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A Guide To Cranes and Derricks
A Guide To Cranes and Derricks
Guide
20
A Guide to
Cranes and Derricks
Acknowledgments
A Guide to Cranes and Derricks was originally prepared by David V. MacCollum, president of David V. MacCollum,
Ltd., of Sierra Vista, Ariz. NCDOL recognizes with much appreciation the contributing organizations that offered and
supplied material and information used in this guide. Wire Rope Slings Pocket Reference Guide extracts shown in the
PDF version of this document are provided on behalf of union ironworkers and their employers by the Institute of the
Ironworking Industry. Figures 14 and 15 were provided courtesy of Award Services Crane Safety Systems, a division of
Ronald M. Ward & Associates Inc. of Orlando, Fla. N.C. Department of Labor employee Bobby Davis incorporated
these documents into this guide, including information from the U.S. Department of Energy (DOE) Hoisting and Rigging
Standard, DOE-STD-1090-2001 www.hss.doe.gov/nuclearsafety/ns/techstds/standard/standard.html#1001. DOEs current Hoisting and Rigging Standard, DOE-STD-1090-2007, can be found at www.hss.doe.gov/nuclearsafety/ns/techstds/standard/std1090-07/index.html. This guide was updated in 2010.
_____
This guide is intended to be consistent with all existing OSHA standards; therefore, if an area is considered by the
reader to be inconsistent with a standard, then the OSHA standard should be followed.
To obtain additional copies of this guide, or if you have questions about North Carolina occupational safety and health standards or rules, please contact:
N.C. Department of Labor
Education, Training and Technical Assistance Bureau
1101 Mail Service Center
Raleigh, NC 27699-1101
Phone: (919) 807-2875 or 1-800-NC-LABOR
____________________
Additional sources of information are listed on the inside back cover of this guide.
____________________
The projected cost of the NCDOL OSH program for federal fiscal year 20102011 is $18,011,652. Federal funding provides approximately 31 percent ($5,501,500) of
this fund.
Revised 10/10
Contents
Part
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1iiv
iii
Foreword
Construction cranes are a common sight on North Carolina city skylines. People watch in amazement as stacks of
material and loads of concrete become our newest buildings. But the very power and size of cranes can pose many dangers to the employees who work in and around them.
A Guide to Cranes and Derricks examines the hazards and describes safety measures the reader can take when implementing a crane safety program for a company. The guide also includes the new standards for cranes in North Carolina.
In North Carolina, N.C. Department of Labor enforces the federal Occupational Safety and Health Act through a state
plan approved by the U.S. Department of Labor. NCDOL offers many educational programs to the public and produces
publications to help inform people about their rights and responsibilities regarding occupational safety and health.
When reading this guide, please remember the mission of the N.C. Department of Labor is greater than just regulatory
enforcement. An equally important goal is to help citizens find ways to create safe and healthy workplaces. Everyone
profits when managers and employees work together for safety. This booklet, like the other educational materials produced by the N.C. Department of Labor, can help.
Cherie Berry
Commissioner of Labor
iv
1
Reasons for Crane Accidents and Preventive Measures
In our highly mechanized world, cranes are the workhorses that have increased productivity and economic growth in
construction, mining, logging, maritime operations, and maintenance of production and service facilities. It is not unusual
in large metropolitan areas to see several crane booms outlined against the skyline within a few blocks of each other and
in rural areas to see cranes performing a great variety of jobs.
Statistics show, however, that there are inherent hazards that occur during normal working circumstances. A crane can
be a very dangerous piece of equipment. Most crippling injuries and deaths from crane accidents can be attributed to several basic hazards.
Those supervising the use of cranes can greatly improve workplace safety by targeting the craning hazards that cause
the most injury and death. Basic hazard prevention measures can be taken to eliminate these hazards. It is important to
ensure the safety of all personnel who may be in the immediate areas where cranes are being operated, not just the riggers, signalers and operators.
Workplace safety is more than complying with a few safety rules. Everyone must be involvedmanagement, supervisors and the work crew. Each has specific safety responsibilities, and a mutual understanding of who is responsible for
what is essential. A fact that is often overlooked is that hazards are the primary cause of most accidents, so hazard prevention is what brings about a safe workplace. But, what is a hazard? How can a hazard be controlled?
As it relates to cranes, a hazard may be thought of as any unsafe condition. Hazards may be present in three forms:
Dormant: A dormant hazard is an undetected hazard created either by design or crane use.
Armed: An armed hazard is a dormant hazard that has become armed and ready to cause harm during certain work
circumstances.
Active: An active hazard is an armed hazard triggered into action by the right combination of factors. At this point it
is too late to take any preventive action to escape injury or avoid death.
To change the design of a crane on a jobsite to make it safer is almost impossible, but there are measures within the
control of every crane owner or user that can be taken to prevent a hazard from becoming armed and active. In decreasing
order of importance, the most effective ways to control hazards are:
1. Eliminate or minimize the hazard. The major effort during the planning phase of any project must be to select appropriate work methods for cranes to eliminate hazards created by particular work circumstances.
2. Guard the hazard. Hazards that cannot be totally eliminated through planning must be reduced to an acceptable level
of risk by the use of appropriate safety devices to guard, isolate or otherwise render the hazard effectively inert or inaccessible. If this cannot be done, then nearby personnel should be protected from the hazard. For example, the employer
should ask the manufacturer to assist in installing guards to provide physical protection against moving parts. Listed
below are other methods of guarding particular hazards or the danger zone they create.
a. Install screens or covers over moving parts.
b. To prevent electrocution when cranes are to be used in the vicinity of overhead energized power lines, have the local
electric utility install line guards or covers on the lines. Use an insulated link on the hoist line to prevent the passage of
electric current from the hook through the load to the person guiding the load on the ground.
c. Install fences, guardrails or other barriers to prevent entry into the danger zone created by the rotating crane cab.
d. Ask the manufacturer to install a crush-resistant cab and restraint system that encloses the operator in a protective
frame to give the operator a place of safety if upset occurs.
3. Give warning. When a hazard cannot be controlled by applying either the first or second method, an active, intercessory warning device should be installed that detects a hazard and emits a timely, audible and/or visual warning signal.
Examples are alarms, horns and flashing lights. Warning systems must emit the standard variety of sounds or flashes so
the meaning of the warning will be understood. Some hazard detection systems not only give audible or visual warnings
but are wired to stop or prohibit movement. On cranes, this is especially important so the boom can be stopped before it
reaches a hazardous position. There are numerous suppliers of such items.
1
Signs and labels are passive warnings. They must be very explicit and state what the hazard is, what harm will result,
and how to avoid the hazard. The signs for life-threatening hazards should be pictorial if possible, with the word DANGER written in white letters on an oval red background with a black border. Signs and labels are not substitutes for eliminating or guarding the hazard. Rather, warnings are best used to make users aware of a specific change of circumstances
that can create a hazardous situation or of a dormant hazard that could not be totally eliminated or controlled. Warnings
should also inform users as to why the specified safeguard must be used.
Requirements for signs and labels are set forth in Occupational Safety and Health Administration (OSHA) standards,
Specifications for Accident Prevention Signs and Tags, 29 CFR 1910.145; Signs, Signals, and Barricades, 29 CFR
1926.200; and Society of Automotive Engineers Recommended Practices (SAE) J115, Safety Signs.
4. Special procedures and training. When a hazard cannot be eliminated or its risk reduced by any of the first three
methods, then planning, special operating procedures, training and audits must be employed to guarantee that a viable,
continuing regimen will effect avoidance of the hazard.
5. Personal protective equipment. Use of gloves, taglines to guide the load, hard hats, safety shoes, aprons, goggles,
safety glasses, lifelines, life jackets and other protective equipment at all appropriate times will also protect users from
injury.
Often a combination of several of these five preventive measures is necessary to control a life-threatening hazard.
In light of all the tower crane fatalities in the news during recent years, as well as a high number of other crane related
fatalities and accidents North Carolina has experienced, it is important that NCDOL be proactive in taking action to
address safety concerns and work to prevent further incidents. Therefore, inspection of tower and mobile crane operation
is now added to our Special Emphasis Program referenced in Operational Procedures Notice (OPN) 123H. This will be an
ongoing effort for inspection of mobile cranes, tower cranes and derricks at job or work sites throughout the state. The
primary focus will be to increase crane inspection activity, training and outreach efforts, and consultative services in this
area. All counties are included in this part of the construction emphasis program. Compliance officers are directed to stop
and conduct inspection activity whenever they see a crane in use (consultation can also stop and offer services).
Mobile cranes include truck-mounted cranes, crawler cranes, locomotive cranes, wheel-mounted cranes and articulating boom cranes. Tower cranes include hammerhead tower cranes, fixed tower cranes, climber tower cranes, luffing boom
tower cranes, self-erector tower cranes and mobile tower cranes.
Compliance inspections will ensure that the operator is adequately trained, the employer/operator are following OSHA
and ANSI requirements for the particular crane they are operating, cranes have been inspected prior to service and on a
daily basis per ANSI and OSHA standards, the crane and operation thereof are in good repair, cranes are receiving
required preventative maintenance, and that proper documentation is maintained by the employer.
The table below presents a summary of North Carolina crane-related accidents for June 1998June 2007. (Reports
indicate date,standard industrial classification (SIC), employee type and age.)
Table 1
North Carolina crane-related accidents
Date
SIC
Accident Description
Employee Type
03/27/07
1791
Crushed by crane
Laborer
25
01/30/06
1622
Laborer
48
12/01/05
5084
Laborer
48
05/07/04
1799
Struck by crane
Rigger/operator
33
09/16/02
1791
Laborer
30
08/01/01
3443
Laborer
20
08/01/01
3443
Laborer
37
03/23/00
1791
Tower erector
26
05/04/00
1791
Struck by crane
Construction worker
34
06/29/98
3441
Material Handler
59
Employee Age
Percent
290
40.3
173
24.1
88
12.2
76
10.6
73
10.2
Other
19
2.6
Total
719
100.0
Table 3
Struck by mobile crane-related occupational injury deaths by industry: United States, 19922002
Number of deaths
Construction
Percent
153
52.8
Manufacturing
44
15.2
35
12.0
Services
20
6.9
Wholesale trade
14
4.8
Mining
12
4.1
2.1
Other
2.1
Total
290
100.0
The following occupational injury and illness source codes for cranes were included: unspecified (3430);
floating (3431); hammerhead (3433); mobile, truck, and rail mounted (3434); portal, tower, and pillar
(3437); and N.E.C. (3439). These specific codes were selected to limit the analysis to types of mobile
cranes. Excluded crane types include gantry (3432); monorail and underhung (3435); overhead (3436);
and storage and retrieval hoist systems (3438).
2
Types of Cranes Generally Used in the Workplace
Rough Terrain and Wheel-Mounted Telescoping Boom
Figure 1
Wheel-Mounted CraneTelescoping Boom (Single Control Station)
Operators station
(Fixed)
Hydraulic Boom
Figure 2
Wheel-Mounted CraneTelescoping Boom (Multiple Control Station)
Operators station
(Fixed)
Latticework Boom
Figure 3
Wheel-Mounted Crane (Multiple Control Station)
Hydraulic Boom
Figure 4
Commercial Truck-Mounted CraneTelescoping Boom
Tower Crane
Figure 5
Hammerhead
Counterjib pendant
Top Tower
Cab
Boom (jib)
Turntable
Counterweight
Counterjib
Concrete footing
Tower Crane
Figure 6
Luffing Boom
Pendant
Boom hoist ropes
A-frame (gantry)
Boom (jib)
Machine
deck
Cab
Turntable
Counterweight
Tower (mast)
Concrete footing
Trolley
Articulated Boom
Figure 7
Commercial Truck-Mounted Remote Control
Trolley Boom
Figure 8
Trolley Boom Crane
3
Analysis of Eight Hazards Common to Most Cranes
This part analyzes eight hazards common to most cranes. Each analysis includes a definition, description, risks presented by the hazard, reasons why the hazard occurs, preventive measures and any applicable OSHA requirements.
The lack of qualifications on the part of crane operators figures prominently into these hazards. The crane owner and
job supervisor must ensure that their crane operators are qualified and competent, not only in machine operations but in
load capacity calculations as well. Minimum competent personnel requirements are included in Part 4.
10 feet in any direction from power lines is an unsafe work area and must be clearly marked off on the ground by marker
tape, fences, barriers, etc. That way, everyone at the worksite has the visual clues to ensure that the crane is positioned so
that the boom and hoist line cannot intrude into the danger zone created by the power lines. Figure 10 shows how to map
this danger zone surrounding power lines so it is impossible for the boom in any position or the hoist line to come closer
than 10 feet and intrude into the danger zone. If the danger zone can be penetrated by a crane boom, the electric utility must
be notified to deenergize, relocate, bury or insulate the lines while the crane is operating in that location.
Figure 10
Power Lines Properly Guarded to Prevent Contact With a Crane
DANGER ZONE
UNSAFE FOR CRANE OPERATIONS
DO NOT lift or make boom movements inside the barricaded area.
Judge accurately clearances between a crane and power lines simply through the use of vision.
See more than one visual target at a time.
Overcome the camouflaging characteristics that trees, buildings and other objects have upon power lines.
Sometimes a crane operator cannot judge the clearance of the boom from the power line because the boom blocks the
operators view to the right. Sole reliance upon the performance of crane operators, riggers and signalers, without any
planning to separate cranes from power lines, has resulted in many deaths.
Pick-and-carry operations with mobile cranes often result in power line contact, even though the same route had been
taken previously. Cage-type boom guards, insulated links and proximity warning devices provide safety backups for operators, but such devices are not substitutes for maintaining the 10-foot clearance, which is most important. Use of these
devices must be consistent with the product manufacturers recommendations.
Truck-mounted trolleys or articulated crane booms that utilize an electrical remote control system to load or unload
bricks, cement block, trusses and other building supplies have also caused many injuries and deaths. In the event the
boom contacts a power line, the individual holding the control box at the end of the electrical control cable is usually
electrocuted instantly. Such equipment should never be used near power lines. A safer purchase choice would be non-conductive, pneumatic-powered or remote radio control systems.
10
Controls for flatbed-mounted cranes that are located where they can be operated by an individual standing on the
ground leaves the operator vulnerable to the initial fault current path in the event the boom strikes a power line.
Table 4 shows the safe working distance from power lines. Figure 11 illustrates the prohibited zone around a power
line.
Table 4
Minimum Clearance Distances From Power Lines
A. While Operating
Voltage
(Nominal, kV, Alternating Current)
Up to 50
10
Over 50 to 200
15
20
25
35
45
Over 1,000
Up to 0.75
Over .75 to 50
Over 50 to 345
10
16
20
Over 1,000
11
Figure 11
Danger Zone for Cranes and Lifting Personnel Near Electrical Transmission Line
Prohibited zone:
See Table 4
Prohibited zone:
See Table 4
12
OSHA Requirements
Always Do
ALWAYS, when in doubt, call the electric company to find out what voltage is on the lines.
ALWAYS ask the electric company to either deenergize and ground the lines or install insulation while you are working near them.
Overloading
Definition
Overloading occurs when the rated capacity of a crane is exceeded while a load is being lifted and maneuvered, resulting in upset or structural failure.
Description
Cranes can easily upset from overloading. On some models the weight of a boom without a load can create an imbalance and cause some high-reach hydraulic cranes to upset when the boom is positioned at a low angle. This has occurred
even with outriggers extended.
Todays crane operator is confronted with a number of variables that affect lifting capacity:
1. The ability to lower a boom increases the radius and reduces its capacity.
2. The ability to extend a hydraulic boom increases the radius and reduces lifting capacity.
13
3. The ability to lower a boom while extending a boom quickly reduces lifting capacity.
4. The cranes tipping capacity can vary when the boom is positioned at the various points of the compass or clock in
relation to its particular carrier frame.
5. The operator may neglect to extend the outriggers and affect the cranes stability.
6. The operator may mistakenly rely upon perception, instinct or experience to determine whether the load is too heavy
and may not respond fast enough when the crane begins to feel light. (Fundamental to a lift are prelift determinations
of the weight of the load and the net capacity of the crane29 CFR 1926.1417(o).)
All of these variables create conditions that lead to operators inadvertently exceeding the rated capacity, tipping the
load and upsetting the crane. The variables may also lead to structural failure of the crane. That is, under certain loads and
at particular configurations, the crane may break before it tips.
Risks Presented by Overloading
It is estimated that one crane upset occurs during every 10,000 hours of crane use. Approximately 3 percent of upsets
result in death, 8 percent in lost time, and 20 percent in damage to property other than the crane. Nearly 80 percent of
these upsets can be attributed to predictable human error when the operator inadvertently exceeds the cranes lifting
capacity. This is why employers must ensure their operators competence (see Table 5).
Table 5
Analysis of 1,000 Crane Upset Occurrences During a 20-Year Period
Approximately
15%
39%
15%
14%
6%
7%
4%
In travel mode
Making swing with outriggers retracted
Making a pick with outriggers retracted
Making a pick or swing with outriggers extended
Making a pick or swing; use of outriggers unknown
Outrigger failure
Other activity
Also reported:
3%
8%
20%
Deaths
Lost-time injuries
Significant property damage other than the crane
OSHA Requirements
15
OSHA Requirements
Two-Blocking
Definition
Two-blocking occurs when the hoist block or hook assembly comes into contact with the boom tip, causing the hoist
line to break and the hook and load to fall, endangering workers below.
Description
Both latticework and hydraulic boom cranes are prone to two-blocking. When two-blocking occurs on latticework
booms, the hoist line picks up the weight of the boom and lets the pendant guys go slack. Often a whip action is created
when a crawler crane with a long boom without a load is walking and the headache ball and empty chokers can drift up
to the boom tip. Ordinarily, while the operator is busy watching the pathway of travel to avoid any rough ground that can
violently jerk the crane, he or she does not watch the boom tip. When a hoist line two-blocks, it assumes the weight of the
boom and relieves the pin-up guys of the load. Then, if the crane crawler goes over a rock or bump, the flypole action of a
long boom is sufficient to break the hoist line. The weight of the load plus the weight of the boom on a latticework boom
(when combined with a little extra stress when lifting a load) can cause the hoist line to break if two-blocking occurs.
The power of the hydraulic rams that extend hydraulic booms is often sufficient to break the hoist line if two-blocking
occurs. If operators fail to pay out the load line while extending the boom, the hoist line can be inadvertently broken. If
the load line breaks while supporting a worker on a boatswains chair or several workers on a floating scaffold or a load
above people, a catastrophe can result. When an operator must use two controls, one for the hoist and one for the
hydraulic boom extension, the chance of error is increased.
In many circumstances, both latticework and hydraulic boom cranes will two-block when the hook is near the tip and
the boom is lowered. Two-blocking incidents can also occur without resulting in actual failure, but causing damage that
will result in failure at a later time.
Risks Presented by Two-Blocking
Hundreds of deaths and crippling injuries have resulted from two-blocking occurrences. Over the years, there have
probably been thousands of two-blocking occurrences that have broken the hoist line. Most occurrences probably went
unrecorded because no one was injured when the hoist line failed and dropped the hook and/or load.
Why Two-Blocking Occurs
Two-blocking occurs because the crane operator is often visually overtaxed. He or she is unable to watch the load and
headache ball or hook simultaneously.
Preventive Measures
Anti-two-blocking devices have long been available, but industry acceptance of these devices as a preventive measure
has lagged. OSHA requires an anti-two-blocking device or a two-block damage prevention feature where cranes are used
to hoist personnel.
There are several ways to prevent two-blocking:
1. An anti-two-blocking device can be used. This device is a weighted ring around the hoist line that is suspended on a
chain from a limit switch attached to the boom tip. When the hoist block or headache ball touches the suspended,
weighted ring, the limit switch opens and an alarm warns the operator. It can also be wired to intercede and stop the
hoisting. The circuitry is no more complex than an electric door bell.
2. On hydraulic cranes the hydraulic valving can be sequenced to pay out the hoist line when the boom is being extended, thus avoiding two-blocking.
16
3. Adequate boom length can be ensured to accommodate both the boom angle and sufficient space for rigging, such as
slings, spreader bars and straps. To avoid bringing the hook and headache ball into contact with the boom tip, a boom
length of 150 percent of the intended lift is required for a boom angle of 45 degrees or more.
OSHA Requirements
Pinchpoints
Definition
There are two types of crane pinchpoints:
1. Within the swinging radius of the rotating superstructure of a crane in areas in which people may be working, is a
pinchpoint where people can be crushed or squeezed between the carrier frame and the crane cab, or the crane cab and
an adjacent wall or other structure.
2. Many unguarded gears, belts, rotating shafts, etc., within the crane are pinchpoints to which employees may be exposed.
Description
A pinchpoint is created by the narrow clearance between the rotating superstructure (cab) of a crane and the stationary
carrier frame. When a crane must be used in a confined space, another dangerous pinchpoint is the close clearance
between the rotating cab/counterweight and a wall, post or other stationary object. This hazard is inherent in rough terrain
cranes, truck-mounted cranes, crawler cranes and other mobile cranes. Many people, especially oilers, have been crushed
by such pinchpoints.
Analysis of such occurrences shows that the victims usually entered the danger zone to access:
In all of the known cases where someone entered the danger zone and was caught in a pinchpoint, the danger zone was
outside the crane operators vision. Survivors have stated that they believed the crane operator was not going to rotate or
slew the boom at that particular moment.
Many unguarded moving parts are found in the machinery space, which serves as a shelter for the engine and hoist system.
Risks Presented by Pinchpoints
Many deaths or serious injuries have been recorded as a result of being crushed between the cab and carrier frame.
Many amputations have been caused by unguarded moving parts within the crane.
Why Workers Are Crushed by the Rotating Cab
Workers have been crushed by the rotating cab because management failed to ensure that the crane was adequately barricaded and that all incentives to enter the swing zone were removed. Crane cabs are usually used for storage of lunch
buckets, tools and supplies. The machinery that runs the crane requires oiling, adjustment and maintenance from time to
time. Workers are, therefore, exposed to the hazard of the rotating cab and the hazard created by the many unguarded
moving parts of the crane.
Preventive Measures
The swing area of the crane cab and counterweight must be barricaded against entry into the danger zone.
17
The removal of water jugs, tool boxes and rigging materials from crane cabs would reduce the incentive to enter the
danger zone.
The installation of rear view mirrors for the crane operator provides an added safeguard so the operator can see into the
turning area of the cab and counterweight.
OSHA Requirements
Obstruction of Vision
Definition
Safe use of a crane is compromised when the vision of an operator, rigger or signaler is blocked, and employees cannot
see what the others are doing.
Description
There are two general categories for obstructions of operators vision:
The crane size alone limits the operators range of vision and creates many blind spots, preventing the rigger, signaler,
oiler and others affected by the cranes movement from having direct eye contact with the crane operator. When a cabcontrolled mobile crane is moved or travels back and forth, the operator must contend with many blind spots on the right
side of the crane.
Many situations arise in craning activities that can almost instantaneously turn a simple lift into a life-taking catastrophe:
1. In many instances the work environment requires that loads be lifted to or from an area that is outside of the view of
the operator. The crane boom may obstruct the operators range of vision on the right side.
2. Often a load is lifted several stories high, and the crane operator must rely upon others to ensure safe movement of
the load being handled.
3. Many people are affected by a cranes movement. Welders with their hoods on, carpenters, ironworkers or other
workers may be working in the immediate vicinity of a crane, preoccupied with their tasks and unaware of the activity
of the crane. They also may be out of the range of vision of the crane operator. Both the lack of awareness on the part
of others and the obstructed vision of the crane operator contribute to craning accidents.
Risks Presented by Obstruction of Vision
When operators, riggers, signalers, oilers and others cannot see each other or the suspended load, the risk of accident
becomes very high.
Why People Are Injured by Movement of the Load or the Crane
People are injured during craning when management fails to provide an effective communication system for the crane
operator and signalers to ensure that all are aware of any changes in circumstances. Often signalers have not been adequately trained to perform their important task.
Preventive Measures
The key to a safe craning operation is the planning of all activities, starting with prejob conferences and continuing
with daily planning to address any changes that need to be made.
To overcome the hazard of blind spots while loads are being lifted, the use of radios and telephones is much more
effective than relying upon several signalers to relay messages by line of sight.
18
The use of automatic travel alarms is an effective way to warn those in the immediate vicinity of crane travel movement in pick-and-carry functions.
It should also be recognized that OSHA requires the windows of cranes to be made of safety glass or the equivalent,
which does not introduce visible distortion that will interfere with the safe operation of the crane.
OSHA Requirements
Description
Latticework booms are disassembled for shortening, lengthening or transporting. Boom collapse occurs on truck- or
crawler-mounted cranes when the boom is lowered to a horizontal position and suspended from the boom tip with pendant guys, but the boom is not blocked. If the lower pins connecting boom sections are knocked out by workers who are
under the boom, the boom can collapse upon them, resulting in death or serious injuries.
Risks Presented by Boom Disassembly
There are at least three circumstances that lead to accidents when latticework boom sections are being dismantled:
1. Workers are unfamiliar with the equipment.
2. A poor location is chosen for dismantling.
3. Not enough time is allotted to meet the task deadline.
Why Workers Are Crushed by Latticework Booms During Disassembly
Workers are crushed during disassembly of latticework booms when there is a lack of supervision to ensure that the
manufacturers disassembly procedures are followed.
Preventive Measures
1. Plan boom disassembly location and procedures that are consistent with the manufacturers instructions.
2. Use blocking or cribbing on each boom section. Figure 12 should be posted in the crane cab and Figure 13 should be
attached to each boom section.
3. Use one of several types of pins that substantially reduce the risk of crushing, such as:
a. Double-ended pins that can be removed while one is standing beside the boom by driving the pin in from the outside. (See Dickie, D.E., Crane Handbook, Figure 3.41 at 78.)
b. Step pins that can only be inserted from inside facing out, and can only be removed by driving from the outside
in. (See Dickie, D.E., Crane Handbook, Figure 3.39 at 78.)
c. Welded lugs that prevent pins from being entered the wrong way. This requires the pin to be inserted inside facing
out and can only be removed by driving it from the outside in. (See Dickie, D.E., Crane Handbook, Figure 3.40 at
78).
d. Screw pins with threads that insert or retract the pin.
4. Post warnings at pin connections. Be sure that comprehensive text warning of this hazard and informing of ways to
avoid it is contained in operators manuals.
OSHA Requirements
20
Figure 12
Unsafe (Upper) and Safe (Lower) Way to Block a Boom Section
21
Figure 13
Sign to Be Attached on Each Boom Section
22
4
Crane Safety Programs
North Carolina Cranes and Derricks Standards
Due to significant changes in construction consensus standards and requests from several industry stakeholders, federal
OSHA has been working since 1998 on an update to 29 CFR Part 1926, Subpart N, designed to protect employees from
the hazards associated with hoisting equipment when used to perform construction activities. These changes will affect
establishments across a variety of different construction industries with work involving cranes and derricks.
In July 2002, OSHA announced its intent to use the negotiated rulemaking process to revise Subpart N and established
the Cranes and Derricks Negotiated Rulemaking Advisory Committee (C-DAC), which comprised members from all sectors of the regulated community and from organized labor. The committee began meeting in August 2003 and completed
its task in July 2004. As a result of these meetings, the committee submitted a proposed revision to Subpart N to OSHA
on July 13, 2004. After years of review, OSHA published a notice of proposed rule in the Federal Register on Oct. 9,
2008.
While nationwide tower crane accidents have been in the news, most of the crane-related injuries and deaths in North
Carolina involve mobile type cranes such as crawler cranes and truck cranes. Two recent tower crane accidentsone in
New York and one in Floridaresulted in multiple fatalities. These events highlighted the inherently dangerous nature of
work involving not only tower cranes but all types of cranes. Although each of these events occurred in states other than
North Carolina, the national interest and concern warrant action.
After five high-profile crane accidents killed 15 people in 2008, Labor Commissioner Cherie Berry was approached by
members of industry and asked to consider enacting updated occupational safety and health standards for those employees in North Carolina who operate and work around cranes. As a result, the commissioner decided to take the proactive
approach and proposed adopting new rules for cranes and derricks that mirror the federal consensus document with some
minor exceptions (e.g., organization and grouping to promote ease in reading and understanding by the regulated community in North Carolina).Federal OSHA has now issued a final rule to update the Cranes and Derricks in Construction standard. OSHA has revised the Cranes and Derricks Standard and related sections of the Construction Standards to update
and specify industry work practices necessary to protect employees during the use of cranes and derricks in construction.
In effort to remain as effective as U.S. Department of Labor, the N.C. Department of Labor repealed its state-specific
standard and adopted the regulation promulgated by the U.S. Department of Labor that became effective Nov. 8, 2010.
Riggers, Signalers and Others
Riggers, signalers and others who work with cranes should have qualifications similar to those of the operator. Just as
an unqualified operator can make a life-threatening error during lifting operations, the inappropriate actions of an inexperienced rigger, signaler or anyone else involved in lifting operations can cause an accident.
Hand Signals
Before any lifts are commenced, all parties, including the crane operator, signalers, riggers and others involved, must
refamiliarize themselves with appropriate hand signals. Often signals vary from job to job and region to region. It is best
to ensure that everyone is familiar with the hand signals outlined in ANSI/ASME B30.5, Mobile and Locomotive Cranes
(see Figure 16). The standard states that When using hand signals, the Standard Method must be used. (29 CFR
1926.1419(c)(1)) The standard references ASME B30.3-2004 and ASME B30.5-2004. (29 CFR 1926.1401)
Signaling Devices
On lifts where the signalers are outside the direct view of the operator due to elevation or in blind areas, either a telephone or radio is necessary. Modes of communication must be agreed upon in preconstruction planning and in the job
hazard analysis.
Lifting Capabilities
During preconstruction planning, lifting requirements should be analyzed by an engineer competent to establish
whether the crane to be used has adequate lifting capability. The job hazard analysis should also verify that the crane to be
used has sufficient boom length for the lift.
Rigging Practices
The requirements for slings to support loads are well defined in OSHA standards 29 CFR 1910.184, and the requirements for rigging equipment are defined in 29 CFR 1926.251 and 29 CFR 1926.1431(g)(3).
Controlling the Load
The use of tag lines to control movement of the load is very important. Normally, when a load is being hoisted, the lay
or twist in wire rope causes rotation when the load becomes suspended. OSHA standard 29 CFR 1910.180(h)(3)(xvi)
states: A tag or restraint line shall be used when rotation of the load is hazardous.
Wire Rope Requirements
It is very important to comply with the crane manufacturers recommendations for the type of wire rope to be used for
various hoist lines or pendants.
Annual Inspections
A number of business firms are certified to perform annual crane inspections. A notice of the current inspection should
be posted in the crane. Cranes that cannot be certified must be removed from service until all necessary repairs are made
and the equipment is reinspected. Annual crane inspections are required by 29 CFR 1910.179(j), 29 CFR 1910.180(d), 29
CFR 1910.181(d) and 29 CFR 1926.1412.
Preventive Maintenance
Cranes require ongoing service and preventive maintenance. Preventive maintenance programs should be documented
according to the crane manufacturers recommendations.
24
Figure 14
Dynamics of Setting Up a Crane
Figure 15
Crane nomenclature
Jib Pendants
Jib Mast
or Stay
Jib, Runner,
Whip or
Auxiliary Line
Headache Ball
Inner Ball
Gantry or A-Frame
Crane Upper or
Upperworks
Carrier
Carrier Frame
Center of Rotation
25
Figure 16
Standard Hand Signals for Controlling Crane Operations
26
27
References
OSHA Requirements
Crane or Derrick Suspended Personnel Platforms, OSHA 3100 (Revised 2002), USDOL/OSHA
29 CFR 1926 Subpart CCCranes and Derricks in Construction, 29 CFR 1926.14001442
North Carolina Occupational Safety and Health Standards for General Industry (29 CFR 1910)
North Carolina Occupational Safety and Health Standards for the Construction Industry (29 CFR 1926)
U.S. Department of Energy (DOE), DOE Standard Hoisting and Rigging (Formerly Hoisting and Rigging Manual), DOESTD-1090-2001, April 2001
Pocket Reference Guide for Power Line Clearance, Construction Safety Council, Hillside, Ill., 800-552-7744
Wire Rope Slings pocket reference guide, Institute of the Ironworking Industry, 202-783-3998
ANSI Standards
ANSI B15.1Safety Standards for Mechanical Power Transmission Apparatus
ANSI C2National Electrical Safety Code
ANSI/IEEE C2 National Electrical Safety Code Interpretations, 19611977 Inclusive
ANSl/IEEE C2 National Electrical Safety Code Interpretations, 19781980 Inclusive, and Interpretations Prior to the 6th
Edition
ANSI Z35.1Specifications for Accident Prevention Signs
28
Bureau of the Construction Manufacturers Association. Power Crane and Shovel Association. Mobile Power Crane and
Excavator Standards. PSCA Standard No. 1.
Dickie, D.E. 1975. Crane Handbook. Construction Safety Association of Ontario.
National Fire Protection Association. Cranes and Hoists. National Electrical Code. Chapter 6, Article 610.
U.S. Army Corps of Engineers. Department of the Army. Safety and Health Requirements Manual. EM 385-1-1.
29
Table of Contents
29 CFR 1926 Subpart CCCranes and Derricks in Construction
29 CFR 1926.1400
29 CFR 1926.1401
29 CFR 1926.1402
29 CFR 1926.1403
29 CFR 1926.1404
29 CFR 1926.1405
Scope.
Definitions.
Ground conditions.
Assembly/Disassemblyselection of manufacturer or employer procedures.
Assembly/Disassemblygeneral requirements (applies to all assembly and disassembly operations).
Disassemblyadditional requirements for dismantling of booms and jibs (applies to both the use of
manufacturer procedures and employer procedures).
29 CFR 1926.1406 Assembly/Disassemblyemployer proceduresgeneral requirements.
29 CFR 1926.1407 Power line safety (up to 350 kV)assembly and disassembly.
29 CFR 1926.1408 Power line safety (up to 350 kV)equipment operations.
29 CFR 1926.1409 Power line safety (over 350 kV).
29 CFR 1926.1410 Power line safety (all voltages)equipment operations closer than the Table A zone.
29 CFR 1926.1411 Power line safetywhile traveling.
29 CFR 1926.1412 Inspections.
29 CFR 1926.1413 Wire ropeinspection.
29 CFR 1926.1414 Wire ropeselection and installation criteria.
29 CFR 1926.1415 Safety devices.
29 CFR 1926.1416 Operational aids.
29 CFR 1926.1417 Operation.
29 CFR 1926.1418 Authority to stop operation.
29 CFR 1926.1419 Signalsgeneral requirements.
29 CFR 1926.1420 Signalsradio, telephone or other electronic transmission of signals.
29 CFR 1926.1421 Signalsvoice signalsadditional requirements.
29 CFR 1926.1422 Signalshand signal chart.
29 CFR 1926.1423 Fall protection.
29 CFR 1926.1424 Work area control.
29 CFR 1926.1425 Keeping clear of the load.
29 CFR 1926.1426 Free fall and controlled load lowering.
29 CFR 1926.1427 Operator qualification and certification.
29 CFR 1926.1428 Signal person qualifications.
29 CFR 1926.1429 Qualifications of maintenance & repair employees.
29 CFR 1926.1430 Training.
29 CFR 1926.1431 Hoisting personnel.
29 CFR 1926.1432 Multiple-crane/derrick liftssupplemental requirements.
29 CFR 1926.1433 Design, construction and testing.
29 CFR 1926.1434 Equipment modifications.
29 CFR 1926.1435 Tower cranes.
29 CFR 1926.1436 Derricks.
29 CFR 1926.1437 Floating cranes/derricks and land cranes/derricks on barges.
29 CFR 1926.1438 Overhead & gantry cranes.
29 CFR 1926.1439 Dedicated pile drivers.
29 CFR 1926.1440 Sideboom cranes.
29 CFR 1926.1441 Equipment with a rated hoisting/lifting capacity of 2,000 pounds or less.
29 CFR 1926.1442 Severability.
Appendix A to Subpart CC of Part 1926Standard Hand Signals
Appendix B to Subpart CC of Part 1926Assembly/DisassemblySample Procedures for Minimizing the Risk of
Unintended Dangerous Boom Movement
Appendix C to Subpart CC of Part 1926Operator CertificationWritten ExaminationTechnical Knowledge Criteria
See complete information and listing of standards at following website: http://www.osha.gov/cranes-derricks/index.html
30
Glossary
Most of these definitions are in the 1926.1401 standard. A few other key terms have been added to this list to assist with
clarification.
1. A/D director (Assembly/Disassembly director) means an individual who meets this subparts requirements for an
A/D director, irrespective of the persons formal job title or whether the person is non-management or management
personnel.
2. Assembly/Disassembly means the assembly and/or disassembly of equipment covered under this standard. With
regard to tower cranes, erecting and climbing replaces the term assembly, and dismantling replaces the term
disassembly. Regardless of whether the crane is initially erected to its full height or is climbed in stages, the
process of increasing the height of the crane is an erection process.
3. Assembly/Disassembly: The assembly and disassembly of equipment covered under this Section. With regard to
tower cranes, erecting and climbing replaces the term assembly, and dismantling replaces the term disassembly.
4. Assembly/Disassembly Supervisor (A/D Supervisor): An individual who meets this Section's requirements for
an A/D supervisor, irrespective of the person's formal job title or whether the person is non-management or management personnel.
5. Attachments means any device that expands the range of tasks that can be done by the equipment. Examples
include, but are not limited to: An auger, drill, magnet, pile-driver, and boom-attached personnel platform.
6. Attachment: Any device that expands the range or tasks that can be done by the equipment. Examples include an
auger, drill, magnet, pile-driver, and boom-attached personnel platform.
7. Audible signal means a signal made by a distinct sound or series of sounds. Examples include, but are not limited
to, sounds made by a bell, horn, or whistle.
8. Audible Signal: A signal made by a distinct sound or series of sounds. Examples include sounds made by a bell,
horn, or whistle.
9. Bird Caging means the twisting of fiber or wire rope in an isolated area in the opposite direction of the rope lay,
thereby causing it to take on the appearance of a bird cage.
10. Blocking (also referred to as cribbing) is wood or other material used to support equipment or a component and
distribute loads to the ground. It is typically used to support lattice boom sections during assembly/disassembly and
under outrigger and stabilizer floats.
11. Blocking (also referred to as cribbing): Wood or other material used to support equipment or a component and
distribute loads to the ground. Blocking is typically used to support latticed boom sections during assembly/disassembly and under outrigger floats.
12. Boatswain's Chair: A single-point adjustable suspension scaffold consisting of a seat or sling (which may be incorporated into a full body harness) designed to support one employee in a sitting position.
13. Bogie means travel bogie, which is defined below.
14. Boom (equipment other than tower crane) means an inclined spar, strut, or other long structural member which supports the upper hoisting tackle on a crane or derrick. Typically, the length and vertical angle of the boom can be varied to achieve increased height or height and reach when lifting loads. Booms can usually be grouped into general
categories of hydraulically extendible, cantilevered type, latticed section, cable supported type or articulating type.
15. Boom (equipment other than tower crane): An inclined spar, strut, or other structural member which supports the
upper hoisting tackle on a crane or derrick. Typically, the length and vertical angle of the boom can be varied to
achieve increased height or height and reach when lifting loads. Booms can usually be grouped into general categories of hydraulically extendible, cantilevered type, latticed section, cable supported type or articulating type.
16. Boom: if the boom (i.e., principle horizontal structure) is fixed, it is referred to as a jib; if it is moveable up and
down, it is referred to as a boom.
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17. Boom Angle Indicator: A device which measures the angle of the boom relative to horizontal.
18. Boom Hoist Limiting Device: A device that disengages boom hoist power when the boom reaches a predetermined
operating angle. It also sets brakes or closes valves to prevent the boom from lowering after power is disengaged.
This includes a boom hoist disengaging device, boom hoist shut-off, boom hoist disconnect, boom hoist hydraulic
relief, boom hoist kick-outs, automatic boom stop device, or derricking limiter.
19. Boom Length Indicator: The length of the permanent part of the boom (such as ruled markings on the boom) or, as
in some computerized systems, the length of the boom with extensions/attachments.
20. Boom Stop: A device that restricts the boom from moving a certain maximum angle and toppling over backward.
This includes boom stops, belly straps with struts/standoff, telescoping boom stops, attachment boom stops, and
backstops.
21. Boom Suspension Systems: A system of pendants, running ropes, sheaves, and other hardware which supports the
boom tip and controls the boom angle.
22. Builder means the builder/constructor of equipment.
23. Center of Gravity: The point in an object around which its weight is evenly distributed, such that if a support is
placed under that point, the object could balance on the support.
24. Certified welder means a welder who meets nationally recognized certification requirements applicable to the task
being performed.
25. Certified Welder: A welder who meets certification requirements applicable to the task being performed, in accordance with the American Welding Society or the American Society of Mechanical Engineers.
26. Climbing: The process in which a tower crane is raised to a new working height, either by adding additional tower
sections to the top of the crane (top climbing), or by a system in which the entire crane is raised inside the structure
(inside climbing).
27. Come-A-Long: A mechanical device typically consisting of a chain or cable attached at each end that is use to facilitate movement of materials through leverage.
28. Competent Person: A person who is capable of identifying existing and predictable hazards in the surroundings or
working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization from
his employer to take prompt corrective measures to eliminate them.
29. Controlled Load Lowering: Lowering a load by means of a mechanical hoist drum device that allows a hoisted load
to be lowered with maximum control using the gear train or hydraulic components of the hoist mechanism.
Controlled load lowering requires the use of the hoist drive motor, rather than the load hoist brake, to lower the
load.
30. Controlling Entity: A prime contractor, general contractor, construction manager or any other legal entity which has
the overall responsibility for the construction of the projects, including its planning, quality and completion.
31. Counterweight: A weight used to supplement the weight of equipment in providing stability for lifting loads by
counterbalancing those loads.
32. Crane/derrick includes all equipment covered by this subpart.
33. Crane Level Indicator: A device for determining true horizontal.
34. Crane, Articulating: A crane whose boom consists of a series of folding, pin-connected structural members, typically manipulated to extend or retract by power from hydraulic cylinders.
35. Crane, Assist: A crane used to assist in assembling or disassembling a crane.
36. Crane, Crawler: Equipment that has a type of base mounting which incorporates a continuous belt of sprocket driven track.
37. Crane, Floating (or Floating Derrick): Equipment designed by the manufacturer (or employer) for marine use by
permanent attachment to a barge, pontoons, vessel or other means of flotation.
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38. Crane, Land (or Land Derrick): Equipment not originally designed by the manufacturer for marine use by permanent attachment to barges, pontoons, vessels, or other means of flotation.
39. Crane, Locomotive: A crane mounted on a base or car equipped for travel on a railroad track.
40. Crane, Mobile: A lifting device incorporating a cable suspended latticed boom or hydraulic telescopic boom
designed to be moved between operating locations by transport over the road. These are referred to in Europe as a
crane mounted on a truck carrier.
41. Crane, Overhead and Gantry includes overhead/bridge cranes, semigantry, cantilever gantry, wall cranes, storage
bridge cranes, launching gantry cranes, and similar equipment, irrespective of whether it travels on tracks, wheels,
or other means.
42. Crane, Portal: A type of crane consisting of a rotating upperstructure, hoist machinery, and boom mounted on top of
a structural gantry which may be fixed in one location or have travel capability. The gantry legs or columns usually
have portal openings in between to allow passage of traffic beneath the gantry.
43. Crane, Side-Boom: A track-type or wheel-type tractor having a boom mounted on the side of the tractor, used for
lifting, lowering, or transporting a load suspended on the load hook. The boom or hook can be lifted or lowered in a
vertical direction only.
44. Crane, Tower: A type of lifting structure which utilizes a vertical mast or tower to support a working boom (jib)
suspended from the working boom. While the working boom may be fixed horizontally or have luffing capability, it
can always rotate about the tower center to swing loads. The tower base may be fixed in one location or ballasted
and moveable between locations.
45. Critical lift: A crane lifting operation involving an exceptional level of risk due to factors such as load weight, lifting height, procedural complications, or proximity to situational hazards. Critical lifts are often identified by conditions exceeding a specified percentage of the crane's rated capacity (75%), however, any more complex issues may
be involved.
46. Crossover Points: The locations on a wire rope which is spooled on a drum where one layer of rope climbs up on
and crosses over the previous layer. This takes place at each flange of the drum as the rope is spooled on the drum,
reaches the flange, and begins to wrap back in the opposite direction.
47. Dedicated Channel: A line of communication assigned by the employer who controls the communication system to
only one signal person and crane/derrick or to a coordinated group of cranes/derricks/signal person(s).
48. Dedicated Pile-Driver: A machine that is designed to function exclusively as a pile-driver. These machines typically
have the ability to both hoist the material that will be pile-driven and to pile-drive that material.
49. Dedicated Spotter (power lines): A person who meets the requirements of 13 NCAC 07F .0905 (signal person qualifications) and whose sole responsibility is to watch the separation between the power line and the equipment, the
load line and the load (including rigging and lifting accessories), and ensure through communication with the operator that the applicable minimum approach distance is not breached.
50. Directly Under the Load: A part or all of an employee is directly beneath the load.
51. Dismantling includes partial dismantling (such as dismantling to shorten a boom or substitute a different component).
52. Drum Rotation Indicator: A device on a crane or hoist which indicates in which direction and at what relative speed
a particular hoist drum is turning.
53. Electrical Contact: When a person, object, or equipment makes contract or comes in close proximity with an energized conductor or equipment that allows the passage of current.
54. Employer-Made Equipment: Equipment designed and built by an employer for its own use.
55. Encroachment: When any part of the crane, load line or load (including rigging and lifting accessories) breaches a
minimum clearance distance that this Section requires to be maintained from a power line.
56. Equipment means equipment covered by this subpart.
57. Equipment Criteria: Instructions, recommendations, limitations and specifications.
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58. Fall Protection Equipment: Guardrail systems, safety net systems, personal fall arrest systems, positioning device
systems or fall restraint systems.
59. Fall Restraint System: A fall protection system that prevents the user from falling any distance. The system is comprised of either a body belt or body harness, along with an anchorage, connectors and other necessary equipment.
The other components typically include a lanyard, and may also include a lifeline and other devices.
60. Fall zone means the area (including but not limited to the area directly beneath the load) in which it is reasonably
foreseeable that partially or completely suspended materials could fall in the event of an accident.
61. Fall Zone: The area (including the area directly beneath the load) in which it is reasonably foreseeable that partially
or completely suspended materials could fall in the event of an accident.
62. Flange Points: A point of contact between rope and drum flange where the rope changes layers.
63. Free Fall (of the load line): When only the brake is used to regulate the descent of the load line (the drive mechanism is not used to drive the load down faster or retard its lowering).
64. Free Surface Effect: Uncontrolled transverse movement of liquids in compartments which reduce a vessel's transverse stability.
65. Functional testing: The testing of a crane, typically done with a light load or no load, to verify the proper operation
of a crane's primary function, i.e. hoisting, braking, booming, swinging, etc. A functional test is contrasted to testing the crane's structural integrity with heavy loads.
66. Hoist: A mechanical device for lifting and lowering loads by winding rope onto or off of a drum.
67. Hoisting: The act of raising, lowering or otherwise moving a load in the air with equipment covered by this Section.
As used in this Section, hoisting can be done by means other than wire rope/hoist drum equipment.
68. Include/including means including, but not limited to.
69. Insulating Link/Device: An insulating device approved by a Nationally Recognized Testing Laboratory, as that term
is defined in 29 CFR 1910.7(b).
70. Jib Stop (a.k.a. Jib Backstop): Is similar to a boom stop but is for a fixed or luffing jib.
71. List: The angle of inclination about the longitudinal axis of a barge, pontoons, vessel or other means of flotation.
72. Load: The weight of the object being lifted or lowered, including the weight of the load-attaching equipment such
as the load block, ropes, slings, shackles, and any other ancillary attachment.
73. Load Moment Indicator (also referred to as Rated Capacity Indicator): A system which aids the equipment operator
by sensing the overturning moment on the equipment, i.e. load X radius. It compares this lifting condition to the
equipment's rated capacity, and indicates to the operator the percentage of capacity at which the equipment is working. Lights, bells, or buzzers may be incorporated as a warning of an approaching overload condition.
74. Load Moment Limiter (also referred to as Rated Capacity Limiter): A system which aids the equipment operator by
sensing the overturning moment on the equipment, i.e. load X radius. It compares this lifting condition to the equipment's rated capacity, and when the rated capacity is reached, it shuts off power to those equipment functions which
can increase the severity of loading on the equipment, e.g., hoisting, telescoping out, or luffing out. Typically, those
functions which decrease the severity of loading on the equipment remain operational, e.g., lowering, telescoping
in, or luffing in.
75. Luffing Jib Limiting Device: Is similar to a boom hoist limiting device, except that it limits the movement of the
luffing jib.
76. Marine Hoisted Personnel Transfer Device: A device, such as a transfer net, that is designed to protect the
employees being hoisted during a marine transfer and to facilitate rapid entry into and exit from the device. Such
devices do not include boatswain's chairs when hoisted by equipment covered by this Section.
77. Marine Worksite: A construction worksite located in, on or above the water.
78. Moving Point-To-Point: The times during which an employee is in the process of going to or from a work station.
34
79. Multi-Purpose Machine: A machine that is designed to be configured in various ways, at least one of which allows
it to hoist (by means of a winch or hook) and horizontally move a suspended load. For example, a machine that can
rotate and can be configured with removable tongs (for use as a forklift) or with a winch pack, a jib with a hook at
the end, or a jib used in conjunction with a winch. When configured with the tongs, it is not covered by this
Section. When configured with a winch pack, a jib with a hook at the end, or a jib used in conjunction with a
winch, it is covered by this Section.
80. Nationally recognized accrediting agency is an organization that, due to its independence and expertise, is widely
recognized as competent to accredit testing organizations. Examples of such accrediting agencies include, but are
not limited to, the National Commission for Certifying Agencies and the American National Standards Institute.
81. Nationally Recognized Accrediting Agency: An organization that is accredited by the National Commission for
Certifying Agencies (NCCA) or the American National Standards Institute (ANSI) to establish standards for and
assess the formal activities of testing organizations applying for or continuing their accreditation.
82. Nonconductive: That, because of the nature and condition of the materials, used, and the conditions of use (including environmental conditions and condition of the material), the object in question has the property of not becoming
energized (that is, it has high dielectric properties offering a high resistance to the passage of current under the conditions of use).
83. Operational aids are devices that assist the operator in the safe operation of the crane by providing information or
automatically taking control of a crane function. These include, but are not limited to, the devices listed in
1926.1416 (listed operational aids).
84. Operational Aids: Devices that assist the operator in the safe operation of the crane by providing information or
automatically taking control of a crane function. These include the devices listed in 13 NCAC 07F .0917 (listed
operational aids).
85. Operational Controls: Levers, switches, pedals and other devices for controlling equipment operation.
86. Operator means a person who is operating the equipment.
87. Paragraph refers to a paragraph in the same section of this subpart that the word paragraph is used, unless otherwise specified.
88. Pendants: Includes both wire and bar types. Wire type pendants mean a fixed length of wire rope with mechanical
fittings at both ends for pinning segments of wire rope together. Bar type pendants mean that instead of wire rope, a
bar is used. Pendants are typically used in a latticed boom crane system to easily change the length of the boom suspension system without completely changing the rope on the drum when the boom length is increased or decreased.
89. Personal Fall Arrest System: A system used to arrest an employee in a fall from a working level. It consists of an
anchorage, connectors, and a body harness and may include a lanyard, deceleration device, lifeline, or a combination of these.
90. Power Lines: Electrical distribution and electrical transmission lines.
91. Procedures include, but are not limited to: Instructions, diagrams, recommendations, warnings, specifications, protocols and limitations.
92. Procedures: Include instructions, diagrams, recommendations, warnings, specifications, protocols, and limitations.
93. Proximity Alarm: A device that provides a warning of proximity to a power line that has been approved by a
Nationally Recognized Testing Laboratory, as that term is defined in 29 CFR 1910.7(b).
94. Qualified Engineer: An engineer that is licensed as a professional engineer with the North Carolina Board of
Examiners for Engineers and Surveyors.
95. Qualified Evaluator (not a third party): A person employed by the signal person's employer who has demonstrated
to his employer that he/she is competent in accurately assessing whether individuals meet the Qualification
Requirements in this Section for a signal person.
96. Qualified Evaluator (third party): An independent entity that has demonstrated to the employer its competence to
accurately assess whether individuals meet the Qualification Requirements in this Section for a signal person.
35
97. Qualified Person: A person who, by possession of a degree, certificate, or professional standing, or who by knowledge, training and experience, successfully demonstrated to his employer an ability to solve/resolve problems relating to the subject matter, the work, or the project.
98. Qualified Rigger: A rigger who meets the criteria for a qualified person.
99. Range control limit device is a device that can be set by an equipment operator to warn that the boom or jib tip is at
a plane or multiple planes.
100. Range Control Warning Device: A device that can be set by an equipment operator to warn that the boom or jib tip
is at a plane or multiple planes.
101. Rated Capacity: The maximum working load permitted by the manufacturer under specified working conditions.
Such working conditions typically include a specific combination of factors such as equipment configuration, radii,
boom length, and other parameters of use.
102. Repetitive Pickup Points: When an operation involves the rope being used on a single layer and being spooled
repetitively over a portion of the drum.
103. Rotation Resistant Rope: A type of wire rope construction which reduces the tendency of a rope to rotate about its
axis under load. Usually, this consists of an inner system of core strands laid in one direction covered by an outer
system of strands laid in the opposite direction.
104. Running Wire Rope: A wire rope that moves over sheaves or drums.
105. Runway: A firm, level surface designed, prepared and designated as a path of travel for the weight and configuration of the crane being used to lift and travel with the crane suspended platform. An existing surface may be used as
long as it meets these criteria.
106. Section means a section of this subpart, unless otherwise specified.
107. Special Hazard Warnings: Warnings of site-specific hazards (for example, proximity of power lines).
108. Stability (flotation device): The tendency of a barge, pontoons, vessel or other means of flotation to return to an
upright position after having been inclined by an external force.
109. Standard Method: The hand signals established in ASME B30.3-2004 and ASME B30.5-2004.
110. Standing Wire Rope: A supporting wire rope which maintains a constant distance between the points of attachment
to the two components connected by the wire rope.
111. Such as means such as, but not limited to.
112. Tagline: A rope (usually fiber) attached to a lifted load for purposes of controlling load spinning and pendular
motions or used to stabilize a bucket or magnet during material handling operations.
113. Tender: An individual responsible for monitoring and communicating with a diver.
114. Tilt Up or Tilt Down Operation: Raising or lowering a load from the horizontal to vertical or vertical to horizontal.
115. Travel Bogie (also referred to as Bogie): An assembly of two or more axles arranged to permit vertical wheel displacement and equalize the loading on the wheels.
116. Trim: The angle of inclination about the transverse axis of a barge, pontoons, vessel or other means of flotation.
117. Two Blocking: A condition in which a component that is uppermost on the hoist line such as the load block, hook
block, overhaul ball, or similar component, comes in contact with the boom tip, fixed upper block or similar component. This binds the system and continued application of power can cause failure of the hoist rope or other component.
118. Unavailable Procedures: Procedures that are no longer available from the manufacturer, or have never been available from the manufacturer.
119. Upperworks (also referred to as Superstructure or Upperstructure): The revolving frame of equipment on which the
engine and operating machinery are mounted along with the operator's cab. The counterweight is typically supported on the rear of the upperstructure and the boom or other front end attachment is mounted on the front.
36
37
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PART 1926[AMENDED]
Subpart AGeneral
1. The authority citation for subpart A
of 29 CFR part 1926 is retained as
follows:
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1926.6
Incorporation by reference.
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1926.602(b), 1926.1433(a), and
1926.1501(a).
(3) PCSA Std. No. 3, Mobile Hydraulic
Excavator Standards, 1969, IBR
approved for 1926.602(b).
(bb) [Reserved.]
(cc) [Reserved.]
(dd) The following material is
available for purchase from the Society
of Automotive Engineers (SAE), 400
Commonwealth Drive, Warrendale, PA
15096; telephone: 18776067323; fax:
7247760790; Web site: http://
www.sae.org/:
(1) SAE 1970 Handbook, IBR
approved for 1926.602(b).
(2) SAE 1971 Handbook, IBR
approved for 1926.1001(h).
(3) SAE J1661971, Trucks and
Wagons, IBR approved for 1926.602(a).
(4) SAE J1681970, Protective
EnclosuresTest Procedures and
Performance Requirements, IBR
approved for 1926.1002(a).
(5) SAE J185 (reaf. May 2003), Access
Systems for Off-Road Machines,
reaffirmed May 2003 (SAE J185 (May
1993)), IBR approved for
1926.1423(c).
(6) SAE J2361971, Self-Propelled
Graders, IBR approved for 1926.602(a).
(7) SAE J2371971, Front End Loaders
and Dozers, IBR approved for
126.602(a).
(8) SAE J319b1971, Self-Propelled
Scrapers, IBR approved for
1926.602(a).
(9) SAE J320a1971, Minimum
Performance Criteria for Roll-Over
Protective Structure for Rubber-Tired,
Self-Propelled Scrapers, IBR approved
for 1926.1001(h).
(10) SAE J321a1970, Fenders for
Pneumatic-Tired Earthmoving Haulage
Equipment, IBR approved for
1926.602(a).
(11) SAE J333a1970, Operator
Protection for Agricultural and Light
Industrial Tractors, IBR approved for
1926.602(a).
(11) SAE J3861969, Seat Belts for
Construction Equipment, IBR approved
for 1926.602(a).
(12) SAE J3941971, Minimum
Performance Criteria for Roll-Over
Protective Structure for Rubber-Tired
Front End Loaders and Robber-Tired
Dozers, IBR approved for
1926.1001(h).
(13) SAE J3951971, Minimum
Performance Criteria for Roll-Over
Protective Structure for Crawler Tractors
and Crawler-Type Loaders, IBR
approved for 1926.1001(h).
(14) SAE J3961971, Minimum
Performance Criteria for Roll-Over
Protective Structure for Motor Graders,
IBR approved for 1926.1001(h).
(15) SAE J3971969, Critical Zone
Characteristics and Dimensions for
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1926.31
48133
[Reserved.]
Subpart LScaffolds
5. The authority citation for subpart L
of 29 CFR part 1926 is revised to read
as follows:
(a) * * *
(2) * * *
(ii) Requirements relating to fall
protection for employees working on
cranes and derricks are provided in
subpart CC of this part.
*
*
*
*
*
(3) * * *
(v) Criteria for steps, handholds,
ladders, and grabrails/guardrails/
railings required by subpart CC are
provided in subpart CC. Sections
1926.502(a), (c) through (e), and (i)
apply to activities covered under
subpart CC unless otherwise stated in
subpart CC. No other paragraphs of
1926.502 apply to subpart CC.
*
*
*
*
*
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conjunction with derricks. Basemounted drum hoists used in
conjunction with derricks must conform
to 1926.1436(e).
Scope.
1926.550
[Redesignated as 1926.1501]
1926.550
[Reserved]
1926.553
*
*
*
*
(c) This section does not apply to
base-mounted drum hoists used in
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1926.600
Equipment.
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1926.753
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Subpart SUnderground
Construction, Caissons, Cofferdams,
and Compressed Air
19. The authority citation for subpart
S of 29 CFR part 1926 is revised to read
as follows:
1926.800
1926.952
Underground construction.
*
*
*
*
(t) Hoisting unique to underground
construction. Employers must comply
with 1926.1501(g) of 1926 subpart
DD. Except as modified by this
paragraph (t), the following provisions
of subpart N of this part apply:
Requirements for material hoists are
found in 1926.552(a) and (b) of this
part. Requirements for personnel hoists
are found in the personnel hoists
requirements of 1926.552(a) and (c)
of this part and in the elevator
requirement of 1926.552(a) and (d) of
this part.
*
*
*
*
*
Subpart TDemolition
21. The authority citation for subpart
S of 29 CFR part 1926 is revised to read
as follows:
*
*
*
*
(c) Mechanical equipment used shall
meet the requirements specified in
subparts N and O and 1926.1501 of
1926 subpart DD.
23. Section 1926.858 is amended by
revising paragraph (b) to read as follows:
1926.858 Removal of walls, floors, and
material with equipment.
*
*
*
*
(b) Cranes, derricks, and other
hoisting equipment used shall meet the
requirements specified in 1926.1501 of
1926 subpart DD.
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Mechanical equipment.
*
*
*
*
(c) Cranes and other lifting
equipment.
(1) All equipment shall comply with
subparts CC and O of this part, as
applicable.
(2) Digger derricks used for augering
holes for poles carrying electric lines,
placing and removing poles, or for
handling associated materials to be
installed or removed from the poles
must comply with 29 CFR 1910.269.
(3) With the exception of equipment
certified for work on the proper voltage,
mechanical equipment shall not be
operated closer to any energized line or
equipment than the clearances set forth
in 1926.950(c) unless, in addition to
the requirements in 1926.1410:
(i) The mechanical equipment is
insulated, or
(ii) The mechanical equipment is
considered as energized.
Note to paragraph (c)(3): In accordance
with 29 CFR 1926.1400(g), compliance with
29 CFR 1910.269(p) will be deemed
compliance with 1926.1407 through
1926.1411, including 1926.1410.
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1926.1400
Scope.
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communicate to the relevant persons,
and enforce, work rules to ensure
compliance with such provisions.
(g) For work covered by subpart V of
this part, compliance with 29 CFR
1910.269(p) is deemed compliance
with 1926.1407 through 1926.1411.
(h) Section 1926.1402 does not apply
to cranes designed for use on railroad
tracks, when used on railroad tracks that
are part of the general railroad system of
transportation that is regulated pursuant
to the Federal Railroad Administration
under 49 CFR part 213, and that comply
with applicable Federal Railroad
Administration requirements. See
1926.1402(f).
1926.1401
Definitions.
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property of not becoming energized
(that is, it has high dielectric properties
offering a high resistance to the passage
of current under the conditions of use).
Operational aids are devices that
assist the operator in the safe operation
of the crane by providing information or
automatically taking control of a crane
function. These include, but are not
limited to, the devices listed in
1926.1416 (listed operational aids).
Operational controls means levers,
switches, pedals and other devices for
controlling equipment operation.
Operator means a person who is
operating the equipment.
Overhead and gantry cranes includes
overhead/bridge cranes, semigantry,
cantilever gantry, wall cranes, storage
bridge cranes, launching gantry cranes,
and similar equipment, irrespective of
whether it travels on tracks, wheels, or
other means.
Paragraph refers to a paragraph in the
same section of this subpart that the
word paragraph is used, unless
otherwise specified.
Pendants includes both wire and bar
types. Wire type: A fixed length of wire
rope with mechanical fittings at both
ends for pinning segments of wire rope
together. Bar type: Instead of wire rope,
a bar is used. Pendants are typically
used in a latticed boom crane system to
easily change the length of the boom
suspension system without completely
changing the rope on the drum when
the boom length is increased or
decreased.
Personal fall arrest system means a
system used to arrest an employee in a
fall from a working level. It consists of
an anchorage, connectors, a body
harness and may include a lanyard,
deceleration device, lifeline, or suitable
combination of these.
Portal crane is a type of crane
consisting of a rotating upperstructure,
hoist machinery, and boom mounted on
top of a structural gantry which may be
fixed in one location or have travel
capability. The gantry legs or columns
usually have portal openings in between
to allow passage of traffic beneath the
gantry.
Power lines means electric
transmission and distribution lines.
Procedures include, but are not
limited to: Instructions, diagrams,
recommendations, warnings,
specifications, protocols and
limitations.
Proximity alarm is a device that
provides a warning of proximity to a
power line and that has been listed,
labeled, or accepted by a Nationally
Recognized Testing Laboratory in
accordance with 29 CFR 1910.7.
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1926.1402
Ground conditions.
(a) Definitions.
(1) Ground conditions means the
ability of the ground to support the
equipment (including slope,
compaction, and firmness).
(2) Supporting materials means
blocking, mats, cribbing, marsh buggies
(in marshes/wetlands), or similar
supporting materials or devices.
(b) The equipment must not be
assembled or used unless ground
conditions are firm, drained, and graded
to a sufficient extent so that, in
conjunction (if necessary) with the use
of supporting materials, the equipment
manufacturers specifications for
adequate support and degree of level of
the equipment are met. The requirement
for the ground to be drained does not
apply to marshes/wetlands.
(c) The controlling entity must:
(1) Ensure that ground preparations
necessary to meet the requirements in
paragraph (b) of this section are
provided.
(2) Inform the user of the equipment
and the operator of the location of
hazards beneath the equipment set-up
area (such as voids, tanks, utilities) if
those hazards are identified in
documents (such as site drawings, asbuilt drawings, and soil analyses) that
are in the possession of the controlling
entity (whether at the site or off-site) or
the hazards are otherwise known to that
controlling entity.
(d) If there is no controlling entity for
the project, the requirement in
paragraph (c)(1) of this section must be
met by the employer that has authority
at the site to make or arrange for ground
preparations needed to meet paragraph
(b) of this section.
(e) If the A/D director or the operator
determines that ground conditions do
not meet the requirements in paragraph
(b) of this section, that persons
employer must have a discussion with
the controlling entity regarding the
ground preparations that are needed so
that, with the use of suitable supporting
materials/devices (if necessary), the
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(a) Supervisioncompetent-qualified
person.
(1) Assembly/disassembly must be
directed by a person who meets the
criteria for both a competent person and
a qualified person, or by a competent
person who is assisted by one or more
qualified persons (A/D director).
(2) Where the assembly/disassembly
is being performed by only one person,
that person must meet the criteria for
both a competent person and a qualified
person. For purposes of this standard,
that person is considered the A/D
director.
(b) Knowledge of procedures. The
A/D director must understand the
applicable assembly/disassembly
procedures.
(c) Review of procedures. The A/D
director must review the applicable
assembly/disassembly procedures
immediately prior to the
commencement of assembly/
disassembly unless the A/D director
understands the procedures and has
applied them to the same type and
configuration of equipment (including
accessories, if any).
(d) Crew instructions.
(1) Before commencing assembly/
disassembly operations, the A/D
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(1) Site and ground bearing
conditions. Site and ground conditions
must be adequate for safe assembly/
disassembly operations and to support
the equipment during assembly/
disassembly (see 1926.1402 for ground
condition requirements).
(2) Blocking material. The size,
amount, condition and method of
stacking the blocking must be sufficient
to sustain the loads and maintain
stability.
(3) Proper location of blocking. When
used to support lattice booms or
components, blocking must be
appropriately placed to:
(i) Protect the structural integrity of
the equipment, and
(ii) Prevent dangerous movement and
collapse.
(4) Verifying assist crane loads. When
using an assist crane, the loads that will
be imposed on the assist crane at each
phase of assembly/disassembly must be
verified in accordance with
1926.1417(o)(3) before assembly/
disassembly begins.
(5) Boom and jib pick points. The
point(s) of attachment of rigging to a
boom (or boom sections or jib or jib
sections) must be suitable for preventing
structural damage and facilitating safe
handling of these components.
(6) Center of gravity.
(i) The center of gravity of the load
must be identified if that is necessary
for the method used for maintaining
stability.
(ii) Where there is insufficient
information to accurately identify the
center of gravity, measures designed to
prevent unintended dangerous
movement resulting from an inaccurate
identification of the center of gravity
must be used. (See Non-mandatory
Appendix B of this subpart for an
example.)
(7) Stability upon pin removal. The
boom sections, boom suspension
systems (such as gantry A-frames and jib
struts), and components must be rigged
or supported to maintain stability upon
the removal of the pins.
(8) Snagging. Suspension ropes and
pendants must not be allowed to catch
on the boom or jib connection pins or
cotter pins (including keepers and
locking pins).
(9) Struck by counterweights. The
potential for unintended movement
from inadequately supported
counterweights and from hoisting
counterweights.
(10) Boom hoist brake failure. Each
time reliance is to be placed on the
boom hoist brake to prevent boom
movement during assembly/
disassembly, the brake must be tested
prior to such reliance to determine if it
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(2) Determine if any part of the
equipment, load line or load (including
rigging and lifting accessories), if
operated up to the equipments
maximum working radius in the work
zone, could get closer than 20 feet to a
power line. If so, the employer must
meet the requirements in Option (1),
Option (2), or Option (3) of this section,
as follows:
(i) Option (1)Deenergize and
ground. Confirm from the utility owner/
operator that the power line has been
deenergized and visibly grounded at the
worksite.
(ii) Option (2)20 foot clearance.
Ensure that no part of the equipment,
load line, or load (including rigging and
lifting accessories), gets closer than 20
feet to the power line by implementing
the measures specified in paragraph (b)
of this section.
(iii) Option (3)Table A clearance.
(A) Determine the lines voltage and
the minimum approach distance
permitted under Table A (see
1926.1408).
(B) Determine if any part of the
equipment, load line or load (including
rigging and lifting accessories), while
operating up to the equipments
maximum working radius in the work
zone, could get closer than the
minimum approach distance of the
power line permitted under Table A (see
1926.1408). If so, then the employer
must follow the requirements in
paragraph (b) of this section to ensure
that no part of the equipment, load line,
or load (including rigging and lifting
accessories), gets closer to the line than
the minimum approach distance.
(b) Preventing encroachment/
electrocution. Where encroachment
precautions are required under Option
(2) or Option (3) of this section, all of
the following requirements must be met:
(1) Conduct a planning meeting with
the operator and the other workers who
will be in the area of the equipment or
load to review the location of the power
line(s), and the steps that will be
implemented to prevent encroachment/
electrocution.
(2) If tag lines are used, they must be
non-conductive.
(3) Erect and maintain an elevated
warning line, barricade, or line of signs,
in view of the operator, equipped with
flags or similar high-visibility markings,
at 20 feet from the power line (if using
Option (2) of this section) or at the
minimum approach distance under
Table A (see 1926.1408) (if using
Option (3) of this section). If the
operator is unable to see the elevated
warning line, a dedicated spotter must
be used as described in
1926.1408(b)(4)(ii) in addition to
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(3) Training under this section must
be administered in accordance with
1926.1430(g).
(h) Devices originally designed by the
manufacturer for use as: A safety device
(see 1926.1415), operational aid, or a
means to prevent power line contact or
electrocution, when used to comply
with this section, must meet the
manufacturers procedures for use and
conditions of use.
up to 50 ....................................................................................................
over 50 to 200 ..........................................................................................
over 200 to 350 ........................................................................................
over 350 to 500 ........................................................................................
over 500 to 750 ........................................................................................
over 750 to 1,000 .....................................................................................
over 1,000 .................................................................................................
10
15
20
25
35
45
(as established by the utility owner/operator or registered professional
engineer who is a qualified person with respect to electrical power
transmission and distribution).
Note: The value that follows to is up to and includes that value. For example, over 50 to 200 means up to and including 200kV.
1926.1409
kV).
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(d)(4)(i) of this section applies only
when working inside the 1926.950
Table V1 clearance distances.
(iii) For work covered by subpart V of
this part involving operations where use
of an insulating link/device is
infeasible, the requirements of
1910.269(p)(4)(iii)(B) or (C) may be
substituted for the requirement in
(d)(4)(i) of this section.
(iv) Until November 8, 2011, the
following procedure may be substituted
for the requirement in paragraph
(d)(4)(i) of this section: All employees,
excluding equipment operators located
on the equipment, who may come in
contact with the equipment, the load
line, or the load must be insulated or
guarded from the equipment, the load
line, and the load. Insulating gloves
rated for the voltage involved are
adequate insulation for the purposes of
this paragraph.
(v) Until November 8, 2013, the
following procedure may be substituted
for the requirement in (d)(4)(i) of this
section:
(A) The employer must use a link/
device manufactured on or before
November 8, 2011, that meets the
definition of an insulating link/device,
except that it has not been approved by
a Nationally Recognized Testing
Laboratory, and that is maintained and
used in accordance with manufacturer
requirements and recommendations,
and is installed at a point between the
end of the load line (or below) and the
load; and
(B) All employees, excluding
equipment operators located on the
equipment, who may come in contact
with the equipment, the load line, or the
load must be insulated or guarded from
the equipment, the load line, and the
load through an additional means other
than the device described in paragraph
(d)(4)(v)(A) of this section. Insulating
gloves rated for the voltage involved are
adequate additional means of protection
for the purposes of this paragraph.
(5) Nonconductive rigging if the
rigging may be within the Table A of
1926.1408 distance during the
operation.
(6) If the equipment is equipped with
a device that automatically limits range
of movement, it must be used and set to
prevent any part of the equipment, load
line, or load (including rigging and
lifting accessories) from breaching the
minimum approach distance established
under paragraph (c) of this section.
(7) If a tag line is used, it must be of
the nonconductive type.
(8) Barricades forming a perimeter at
least 10 feet away from the equipment
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TABLE TMINIMUM CLEARANCE DISTANCES WHILE TRAVELING WITH NO LOAD
Voltage
(nominal, kV, alternating current)
up to 0.75 .................................................................................................
over .75 to 50 ...........................................................................................
over 50 to 345 ..........................................................................................
over 345 to 750 ........................................................................................
Over 750 to 1,000 ....................................................................................
Over 1,000 ................................................................................................
4
6
10
16
20
(as established by the utility owner/operator or registered professional
engineer who is a qualified person with respect to electrical power
transmission and distribution).
1926.1412
Inspections.
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equipment manufacturers
recommendations, both before each shift
and after each move and setup.
(xii) Operator cab windows for
significant cracks, breaks, or other
deficiencies that would hamper the
operators view.
(xiii) Rails, rail stops, rail clamps and
supporting surfaces when the
equipment has rail traveling. This
paragraph does not apply to the
inspection of rails, rail stops, rail
clamps and supporting surfaces when
the railroad tracks are part of the general
railroad system of transportation that is
regulated pursuant to the Federal
Railroad Administration under 49 CFR
part 213.
(xiv) Safety devices and operational
aids for proper operation.
(2) If any deficiency in paragraphs
(d)(1)(i) through (xiii) of this section (or
in additional inspection items required
to be checked for specific types of
equipment in accordance with other
sections of this standard) is identified,
an immediate determination must be
made by the competent person as to
whether the deficiency constitutes a
safety hazard. If the deficiency is
determined to constitute a safety hazard,
the equipment must be taken out of
service until it has been corrected. See
1926.1417.
(3) If any deficiency in paragraph
(d)(1)(xiv) of this section (safety
devices/operational aids) is identified,
the action specified in 1926.1415 and
1926.1416 must be taken prior to using
the equipment.
(e) Monthly.
(1) Each month the equipment is in
service it must be inspected in
accordance with paragraph (d) of this
section (each shift).
(2) Equipment must not be used until
an inspection under this paragraph
demonstrates that no corrective action
under paragraphs (d)(2) and (3) of this
section is required.
(3) Documentation.
(i) The following information must be
documented and maintained by the
employer that conducts the inspection:
(A) The items checked and the results
of the inspection.
(B) The name and signature of the
person who conducted the inspection
and the date.
(ii) This document must be retained
for a minimum of three months.
(f) Annual/comprehensive.
(1) At least every 12 months the
equipment must be inspected by a
qualified person in accordance with
paragraph (d) of this section (each shift)
except that the corrective action set
forth in paragraphs (f)(4), (f)(5), and
(f)(6) of this section must apply in place
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1926.1413
Wire ropeinspection.
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determines under paragraph (c)(3)(ii) of
this section must be monitored.
(3) Wire ropes on equipment must not
be used until an inspection under this
paragraph demonstrates that no
corrective action under paragraph (a)(4)
of this section is required.
(4) The inspection must be
documented according to
1926.1412(e)(3) (monthly inspection
documentation).
(c) Annual/comprehensive.
(1) At least every 12 months, wire
ropes in use on equipment must be
inspected by a qualified person in
accordance with paragraph (a) of this
section (shift inspection).
(2) In addition, at least every 12
months, the wire ropes in use on
equipment must be inspected by a
qualified person, as follows:
(i) The inspection must be for
deficiencies of the types listed in
paragraph (a)(2) of this section.
(ii) The inspection must be complete
and thorough, covering the surface of
the entire length of the wire ropes, with
particular attention given to all of the
following:
(A) Critical review items listed in
paragraph (a)(3) of this section.
(B) Those sections that are normally
hidden during shift and monthly
inspections.
(C) Wire rope subject to reverse bends.
(D) Wire rope passing over sheaves.
(iii) Exception: In the event an
inspection under paragraph (c)(2) of this
section is not feasible due to existing
set-up and configuration of the
equipment (such as where an assist
crane is needed) or due to site
conditions (such as a dense urban
setting), such inspections must be
conducted as soon as it becomes
feasible, but no longer than an
additional 6 months for running ropes
and, for standing ropes, at the time of
disassembly.
(3) If a deficiency is identified, an
immediate determination must be made
by the qualified person as to whether
the deficiency constitutes a safety
hazard.
(i) If the deficiency is determined to
constitute a safety hazard, operations
involving use of the wire rope in
question must be prohibited until:
(A) The wire rope is replaced (see
1926.1417), or
(B) If the deficiency is localized, the
problem is corrected by severing the
wire rope in two; the undamaged
portion may continue to be used.
Joining lengths of wire rope by splicing
is prohibited. If a rope is shortened
under this paragraph, the employer
must ensure that the drum will still
have two wraps of wire when the load
and/or boom is in its lowest position.
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1926.1415
Safety devices.
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or similar component). The device(s)
must prevent such damage at all points
where two-blocking could occur.
Temporary alternative measures:
Clearly mark the cable (so that it can
easily be seen by the operator) at a point
that will give the operator sufficient
time to stop the hoist to prevent twoblocking, and use a spotter when
extending the boom.
(ii) Lattice boom cranes.
(A) Lattice boom cranes manufactured
after Feb 28, 1992, must be equipped
with a device that either automatically
prevents damage and load failure from
contact between the load block,
overhaul ball, or similar component,
and the boom tip (or fixed upper block
or similar component), or warns the
operator in time for the operator to
prevent two-blocking. The device must
prevent such damage/failure or provide
adequate warning for all points where
two-blocking could occur.
(B) Lattice boom cranes and derricks
manufactured after November 8, 2011
must be equipped with a device which
automatically prevents damage and load
failure from contact between the load
block, overhaul ball, or similar
component, and the boom tip (or fixed
upper block or similar component). The
device(s) must prevent such damage/
failure at all points where two-blocking
could occur.
(C) Exception. The requirements in
paragraphs (d)(3)(ii)(A) and (B) of this
section do not apply to such lattice
boom equipment when used for
dragline, clamshell (grapple), magnet,
drop ball, container handling, concrete
bucket, marine operations that do not
involve hoisting personnel, and pile
driving work.
(D) Temporary alternative measures.
Clearly mark the cable (so that it can
easily be seen by the operator) at a point
that will give the operator sufficient
time to stop the hoist to prevent twoblocking, or use a spotter.
(iii) Articulating cranes manufactured
after December 31, 1999, that are
equipped with a load hoist must be
equipped with a device that
automatically prevents damage from
contact between the load block,
overhaul ball, or similar component,
and the boom tip (or fixed upper block
or similar component). The device must
prevent such damage at all points where
two-blocking could occur. Temporary
alternative measures: When twoblocking could only occur with
movement of the load hoist, clearly
mark the cable (so that it can easily be
seen by the operator) at a point that will
give the operator sufficient time to stop
the hoist to prevent two-blocking, or use
a spotter. When two-blocking could
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Operation.
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(x) The brakes must be adjusted in
accordance with manufacturer
procedures to prevent unintended
movement.
(y) The operator must obey a stop (or
emergency stop) signal, irrespective of
who gives it.
(z) Swinging locomotive cranes. A
locomotive crane must not be swung
into a position where railway cars on an
adjacent track could strike it, until it is
determined that cars are not being
moved on the adjacent track and that
proper flag protection has been
established.
(aa) Counterweight/ballast.
(1) The following applies to
equipment other than tower cranes:
(i) Equipment must not be operated
without the counterweight or ballast in
place as specified by the manufacturer.
(ii) The maximum counterweight or
ballast specified by the manufacturer for
the equipment must not be exceeded.
(2) Counterweight/ballast
requirements for tower cranes are
specified in 1926.1435(b)(8).
1926.1418
1926.1419 Signalsgeneral
requirements.
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Fall protection.
(a) Application.
(1) Paragraphs (b), (c)(3), (e) and (f) of
this section apply to all equipment
covered by this subpart except tower
cranes.
(2) Paragraphs (c)(1), (c)(2), (d), (g), (j)
and (k) of this section apply to all
equipment covered by this subpart.
(3) Paragraphs (c)(4) and (h) of this
section apply only to tower cranes.
(b) Boom walkways.
(1) Equipment manufactured after
November 8, 2011 with lattice booms
must be equipped with walkways on the
boom(s) if the vertical profile of the
boom (from cord centerline to cord
centerline) is 6 or more feet.
(2) Boom walkway criteria.
(i) The walkways must be at least 12
inches wide.
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mounted) poses a reasonably foreseeable
risk of:
(i) Striking and injuring an employee;
or
(ii) Pinching/crushing an employee
against another part of the equipment or
another object.
(2) To prevent employees from
entering these hazard areas, the
employer must:
(i) Train each employee assigned to
work on or near the equipment
(authorized personnel) in how to
recognize struck-by and pinch/crush
hazard areas posed by the rotating
superstructure.
(ii) Erect and maintain control lines,
warning lines, railings or similar
barriers to mark the boundaries of the
hazard areas. Exception: When the
employer can demonstrate that it is
neither feasible to erect such barriers on
the ground nor on the equipment, the
hazard areas must be clearly marked by
a combination of warning signs (such as
DangerSwing/Crush Zone) and high
visibility markings on the equipment
that identify the hazard areas. In
addition, the employer must train each
employee to understand what these
markings signify.
(3) Protecting employees in the hazard
area.
(i) Before an employee goes to a
location in the hazard area that is out of
view of the operator, the employee (or
someone instructed by the employee)
must ensure that the operator is
informed that he/she is going to that
location.
(ii) Where the operator knows that an
employee went to a location covered by
paragraph (a)(1) of this section, the
operator must not rotate the
superstructure until the operator is
informed in accordance with a prearranged system of communication that
the employee is in a safe position.
(b) Where any part of a crane/derrick
is within the working radius of another
crane/derrick, the controlling entity
must institute a system to coordinate
operations. If there is no controlling
entity, the employer (if there is only one
employer operating the multiple pieces
of equipment), or employers, must
institute such a system.
1926.1425
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military is considered qualified if he/
she has a current operator qualification
issued by the U.S. military for operation
of the equipment. An employee of the
U.S. military is a Federal employee of
the Department of Defense or Armed
Forces and does not include employees
of private contractors.
(2) A qualification under this
paragraph is:
(i) Not portable. Such a qualification
meets the requirements of paragraph (a)
of this section only where the operator
is employed by (and operating the
equipment for) the employer that issued
the qualification.
(ii) Valid for the period of time
stipulated by the issuing entity.
(e) Option (4): Licensing by a
government entity.
(1) For purposes of this section, a
government licensing department/office
that issues operator licenses for
operating equipment covered by this
standard is considered a government
accredited crane operator testing
organization if the criteria in paragraph
(e)(2) of this section are met.
(2) Licensing criteria.
(i) The requirements for obtaining the
license include an assessment, by
written and practical tests, of the
operator applicant regarding, at a
minimum, the knowledge and skills
listed in paragraphs (j)(1) and (2) of this
section.
(ii) The testing meets industry
recognized criteria for written testing
materials, practical examinations, test
administration, grading, facilities/
equipment and personnel.
(iii) The government authority that
oversees the licensing department/
office, has determined that the
requirements in paragraphs (e)(2)(i) and
(ii) of this section have been met.
(iv) The licensing department/office
has testing procedures for re-licensing
designed to ensure that the operator
continues to meet the technical
knowledge and skills requirements in
paragraphs (j)(1) and (2) of this section.
(3) A license issued by a government
accredited crane operator testing
organization that meets the
requirements of this option:
(i) Meets the operator qualification
requirements of this section for
operation of equipment only within the
jurisdiction of the government entity.
(ii) Is valid for the period of time
stipulated by the licensing department/
office, but no longer than 5 years.
(f) Pre-qualification/certification
training period. An employee who is not
qualified or certified under this section
is permitted to operate equipment only
as an operator-in-training and only
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1926.1428
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brake does not hold, a repair is
necessary. See 1926.1417(f) and (j) for
additional requirements.
(ii) Where available, the
manufacturers emergency procedures
for halting unintended equipment
movement.
(d) Competent persons and qualified
persons. The employer must train each
competent person and each qualified
person regarding the requirements of
this subpart applicable to their
respective roles.
(e) Crush/pinch points. The employer
must train each employee who works
with the equipment to keep clear of
holes, and crush/pinch points and the
hazards addressed in 1926.1424 (Work
area control).
(f) Tag-out. The employer must train
each operator and each additional
employee authorized to start/energize
equipment or operate equipment
controls (such as maintenance and
repair employees), in the tag-out and
start-up procedures in 1926.1417(f)
and (g).
(g) Training administration.
(1) The employer must evaluate each
employee required to be trained under
this subpart to confirm that the
employee understands the information
provided in the training.
(2) The employer must provide
refresher training in relevant topics for
each employee when, based on the
conduct of the employee or an
evaluation of the employees
knowledge, there is an indication that
retraining is necessary.
(3) Whenever training is required
under subpart CC, the employer must
provide the training at no cost to the
employee.
1926.1431
Hoisting personnel.
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(ii) The following conditions must be
determined by a competent person to
exist before the lift of personnel
proceeds:
(A) Hoist ropes must be free of
deficiencies in accordance with
1926.1413(a).
(B) Multiple part lines must not be
twisted around each other.
(C) The primary attachment must be
centered over the platform.
(D) If the load rope is slack, the
hoisting system must be inspected to
ensure that all ropes are properly seated
on drums and in sheaves.
(6) Any condition found during the
trial lift and subsequent inspection(s)
that fails to meet a requirement of this
standard or otherwise creates a safety
hazard must be corrected before hoisting
personnel. (See 1926.1417 for tag-out
and related requirements.)
(i) [Reserved.]
(j) Proof testing.
(1) At each jobsite, prior to hoisting
employees on the personnel platform,
and after any repair or modification, the
platform and rigging must be proof
tested to 125 percent of the platforms
rated capacity. The proof test may be
done concurrently with the trial lift.
(2) The platform must be lowered by
controlled load lowering, braked, and
held in a suspended position for a
minimum of five minutes with the test
load evenly distributed on the platform.
(3) After proof testing, a competent
person must inspect the platform and
rigging to determine if the test has been
passed. If any deficiencies are found
that pose a safety hazard, the platform
and rigging must not be used to hoist
personnel unless the deficiencies are
corrected, the test is repeated, and a
competent person determines that the
test has been passed. (See 1926.1417
for tag-out and related requirements.)
(4) Personnel hoisting must not be
conducted until the competent person
determines that the platform and rigging
have successfully passed the proof test.
(k) Work practices.
(1) Hoisting of the personnel platform
must be performed in a slow, controlled,
cautious manner, with no sudden
movements of the equipment or the
platform.
(2) Platform occupants must:
(i) Keep all parts of the body inside
the platform during raising, lowering,
and horizontal movement. This
provision does not apply to an occupant
of the platform when necessary to
position the platform or while
performing the duties of a signal person.
(ii) Not stand, sit on, or work from the
top or intermediate rail or toeboard, or
use any other means/device to raise
their working height.
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one or more qualified persons (lift
director).
(2) The lift director must review the
plan in a meeting with all workers who
will be involved with the operation.
1926.1433
testing.
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the rejection in a written response. If the
manufacturer rejects the proposal but
does not explain the reasons for the
rejection in writing, the employer may
treat this as a manufacturer refusal to
review the request under paragraph
(a)(2) of this section.
(c) The provisions in paragraphs (a)
and (b) of this section do not apply to
modifications made or approved by the
U.S. military.
1926.1435
Tower cranes.
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means. This information must be
provided to the operator prior to the lift.
(f) Inspections.
(1) Section 1926.1412 (Inspections)
applies to tower cranes, except that the
term assembly is replaced by
erection. Section 1926.1413 (Wire
ropeinspection) applies to tower
cranes.
(2) Pre-erection inspection. Before
each crane component is erected, it
must be inspected by a qualified person
for damage or excessive wear.
(i) The qualified person must pay
particular attention to components that
will be difficult to inspect thoroughly
during shift inspections.
(ii) If the qualified person determines
that a component is damaged or worn to
the extent that it would create a safety
hazard if used on the crane, that
component must not be erected on the
crane unless it is repaired and, upon
reinspection by the qualified person,
found to no longer create a safety
hazard.
(iii) If the qualified person determines
that, though not presently a safety
hazard, the component needs to be
monitored, the employer must ensure
that the component is checked in the
monthly inspections. Any such
determination must be documented, and
the documentation must be available to
any individual who conducts a monthly
inspection.
(3) Post-erection inspection. In
addition to the requirements in
1926.1412(c), the following
requirements must be met:
(i) A load test using certified weights,
or scaled weights using a certified scale
with a current certificate of calibration,
must be conducted after each erection.
(ii) The load test must be conducted
in accordance with the manufacturers
instructions when available. Where
these instructions are unavailable, the
test must be conducted in accordance
with written load test procedures
developed by a registered professional
engineer familiar with the type of
equipment involved.
(4) Monthly. The following additional
items must be included:
(i) Tower (mast) bolts and other
structural bolts (for loose or dislodged
condition) from the base of the tower
crane up or, if the crane is tied to or
braced by the structure, those above the
upper-most brace support.
(ii) The upper-most tie-in, braces,
floor supports and floor wedges where
the tower crane is supported by the
structure, for loose or dislodged
components.
(5) Annual. In addition to the items
that must be inspected under
1926.1412(f), all turntable and tower
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the maximum allowable working radius
for the test load.
(C) Booming the derrick up and down
within the allowable working radius for
the test load.
(D) Lowering, stopping and holding
the load with the brake(s).
(iii) The derrick must not be used
unless the competent person determines
that the test has been passed.
(4) Documentation. Tests conducted
under this paragraph must be
documented. The document must
contain the date, test results and the
name of the tester. The document must
be retained until the derrick is re-tested
or dismantled, whichever occurs first.
All such documents must be available,
during the applicable document
retention period, to all persons who
conduct inspections in accordance with
1926.1412.
(h) Load testing repaired or modified
derricks. Derricks that have had repairs,
modifications or additions affecting the
derricks capacity or safe operation must
be evaluated by a qualified person to
determine if a load test is necessary. If
it is, load testing must be conducted and
documented in accordance with
paragraph (g) of this section.
(i) [Reserved.]
(j) Power failure procedures. If power
fails during operations, the derrick
operator must safely stop operations.
This must include:
(1) Setting all brakes or locking
devices.
(2) Moving all clutch and other power
controls to the off position.
(k) Use of winch heads.
(1) Ropes must not be handled on a
winch head without the knowledge of
the operator.
(2) While a winch head is being used,
the operator must be within reach of the
power unit control lever.
(l) [Reserved.]
(m) Securing the boom.
(1) When the boom is being held in a
fixed position, dogs, pawls, or other
positive holding mechanisms on the
boom hoist must be engaged.
(2) When taken out of service for 30
days or more, the boom must be secured
by one of the following methods:
(i) Laid down.
(ii) Secured to a stationary member, as
nearly under the head as possible, by
attachment of a sling to the load block.
(iii) For guy derricks, lifted to a
vertical position and secured to the
mast.
(iv) For stiffleg derricks, secured
against the stiffleg.
(n) The process of jumping the derrick
must be supervised by the A/D director.
(o) Derrick operations must be
supervised by a competent person.
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TABLE M1
Rated capacity
Equipment designed
for marine use by
permanent attachment (other than
derricks):
25 tons or less ..........
Over 25 tons .............
Derricks designed for
marine use by permanent attachment:
Any rated capacity ....
Maximum
allowable
list
(degrees)
Maximum
allowable
trim
(degrees)
5
7
5
7
10
10
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section is performed by the equipment
manufacturer, or a qualified person who
Wind
Minimum has expertise with respect to both land
Operated at
speed
freeboard crane/derrick capacity and the stability
(mph)
(ft)
of vessels/flotation devices.
(3) For list and trim.
Rated capacity ..........
60
2
(i) The maximum allowable list and
Rated capacity plus
25% .......................
60
1 the maximum allowable trim for the
High boom, no load ..
60
2 barge, pontoon, vessel or other means of
flotation must not exceed the amount
necessary to ensure that the conditions
TABLE M3
in paragraph (n)(4) of this section are
met. In addition, the maximum
Wind
allowable list and the maximum
Operated at
speed
allowable trim does not exceed the least
of the following: 5 degrees, the amount
For backward stability of the boom:
High boom, no load, full back list 90 mph. specified by the crane/derrick
(least stable condition).
manufacturer, or, when, an amount is
not so specified, the amount specified
(4) If the equipment is employerby the qualified person.
made, it must not be used unless the
(ii) The maximum allowable list and
employer has documents demonstrating the maximum allowable trim for the
that the load charts and applicable
land crane/derrick does not exceed the
parameters for use meet the
amount specified by the crane/derrick
requirements of paragraphs (m)(1)
manufacturer, or, when, an amount is
through (3) of this section. Such
not so specified, the amount specified
documents must be signed by a
by the qualified person.
(4) For the following conditions:
registered professional engineer who is
(i) All deck surfaces of the barge,
a qualified person with respect to the
pontoons, vessel or other means of
design of this type of equipment
flotation used are above water.
(including the means of flotation).
(ii) The entire bottom area of the
(5) The employer must ensure that the
barge, pontoons, vessel or other means
barge, pontoons, vessel or other means
of flotation used is submerged.
of flotation used:
(5) Physical attachment, corralling,
(i) Are structurally sufficient to
rails system and centerline cable system
withstand the static and dynamic loads
meet the requirements in Option (1),
of the crane/derrick when operating at
Option (2), Option (3), or Option (4) of
the crane/derricks maximum rated
this section, and that whichever option
capacity with all planned and actual
deck loads and ballasted compartments. is used also meets the requirements of
paragraph (n)(5)(v) of this section.
(ii) Have a subdivided hull with one
(i) Option (1)Physical attachment.
or more longitudinal watertight
The crane/derrick is physically attached
bulkheads for reducing the free-surface
to the barge, pontoons, vessel or other
effect.
means of flotation. Methods of physical
(iii) Have access to void
attachment include crossed-cable
compartments to allow for inspection
systems attached to the crane/derrick
and pumping.
(n) Land cranes/derricks. For land
and vessel/flotation device, bolting or
cranes/derricks used on barges,
welding the crane/derrick to the vessel/
pontoons, vessels or other means of
flotation device, strapping the crane/
flotation, the employer must ensure
derrick to the vessel/flotation device
that:
with chains, or other methods of
(1) The rated capacity of the
physical attachment.
(ii) Option (2)Corralling. The crane/
equipment (including but not limited to
derrick is prevented from shifting by
modification of load charts) applicable
installing barricade restraints (i.e., a
for use on land is reduced to:
(i) Account for increased loading from corralling system). Employers must
list, trim, wave action, and wind.
ensure that corralling systems do not
(ii) Be applicable to a specified
allow the equipment to shift by any
location(s) on the specific barge,
amount of shifting in any direction.
pontoons, vessel or other means of
(iii) Option (3)Rails. The crane/
flotation that will be used, under the
derrick must be prevented from shifting
environmental conditions expected and by being mounted on a rail system.
encountered.
Employers must ensure that rail clamps
(iii) The conditions required in
and rail stops are used unless the
paragraphs (n)(3) and (n)(4) of this
system is designed to prevent movement
section are met.
during operation by other means.
(2) The rated capacity modification
(iv) Option (4)Centerline cable
required in paragraph (n)(1) of this
system. The crane/derrick is prevented
TABLE M2
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1926.1438
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(iv) Hydraulic.
(v) Combination.
(8) The significance of the instruments and
gauge readings.
(9) The effects of thermal expansion and
contraction in hydraulic cylinders.
(10) Background information necessary to
understand the requirements of pre-operation
and inspection.
(11) How to use the safety devices and
operational aids required under 1926.1415
and 1926.1416.
(12) The difference between duty-cycle and
lifting operations.
(13) How to calculate net capacity for every
possible configuration of the equipment
using the manufacturers load chart.
(14) How to use manufacturer-approved
attachments and their effect on the
equipment.
(15) How to obtain dimensions, weight,
and center of gravity of the load.
(16) The effects of dynamic loading from:
(i) Wind.
(ii) Stopping and starting.
(iii) Impact loading.
(iv) Moving with the load.
(17) The effect of side loading.
(18) The principles of backward stability.
(b) Site information.
(1) How to identify the suitability of the
supporting ground/surface to support the
expected loads of the operation. Elements
include:
(i) Weaknesses below the surface (such as
voids, tanks, loose fill).
(ii) Weaknesses on the surface (such as
retaining walls, slopes, excavations,
depressions).
(2) Proper use of mats, blocking/cribbing,
outriggers, stabilizers, or crawlers.
(3) Identification of site hazards such as
power lines, piping, and traffic.
(4) How to review operation plans with
supervisors and other workers (such as the
signal person), including how to determine
working height, boom length, load radius,
and travel clearance.
(5) How to determine if there is adequate
room for extension of crawlers or outriggers/
stabilizers and counterweights.
(c) Operations.
(1) How to pick, carry, swing and place the
load smoothly and safely on rubber tires and
on outriggers/stabilizers or crawlers (where
applicable).
(2) How to communicate at the site with
supervisors, the crew and the signal person.
(3) Proper procedures and methods of
reeving wire ropes and methods of reeving
multiple-part lines and selecting the proper
load block and/or ball.
(4) How to react to changes in conditions
that affect the safe operation of the
equipment.
(5) How to shut down and secure the
equipment properly when leaving it
unattended.
(6) Know how to apply the manufacturers
specifications for operating in various
weather conditions, and understand how
environmental conditions affect the safe
operation of the equipment.
(7) How to properly level the equipment.
(8) How to verify the weight of the load
and rigging prior to initiating the lift.
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(4) Know how to use the load chart
together with the load indicators and/or load
moment devices.
[FR Doc. 201017818 Filed 72810; 8:45 am]
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DOE-STD-1090-2001
CHAPTER 1
TERMINOLOGY AND DEFINITIONS
The following are specialized terms commonly
used when discussing hoisting and rigging
operations. Many may not be used in this
standard but are included for general
information. The terms are arranged in
alphabetical order. Illustrations are included for
clarity.
1-1
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
BRAKING, DYNAMIC: A method of
controlling crane motor speeds when in the
overhauling condition to provide a retarding
force.
Chapter 1
Terminology and Definitions
1-2
DOE-STD-1090-2001
COME-ALONG: A portable, hand-operated
device consisting of a housing, a length of chain
or wire rope, two hooks, and a ratcheting lever,
that is used for miscellaneous pulling.
1-3
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
o
DEFLECTION:
Chapter 1
Terminology and Definitions
1-4
DOE-STD-1090-2001
DRAGLINE: Wire rope used to pull an
excavating or drag bucket.
1-5
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
GROOVED DRUM: Drum with grooved outer
surface to accommodate and guide a rope.
INTERNAL-COMBUSTION ENGINE
TRUCK: A truck in which the power source is
a gas or diesel engine.
Left Lay:
Right Lay:
o
Chapter 1
Terminology and Definitions
1-6
DOE-STD-1090-2001
LIFT:
o
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1-7
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
PRECISION LOAD POSITIONING
DEVICES: A rigging accessory designed
specifically to precisely raise and lower a load
through a limited range of lifting/lowering
motion (stroke). Standards units typically have
12 in. (30 cm) stroke and can position a load
within 0.001 in. (0.025 mm). These devices
commonly include a built-in load scale and in
such cases may also serve as a load-indicating
device.
NONDESTRUCTIVE EXAMINATION
(NDE): The development and application of
technical methods to examine materials or
components, in ways that do not impair future
usefulness and serviceability, in order to detect,
locate, measure, and evaluate discontinuities,
defects, and other imperfections; to assess
integrity, properties, and composition; and to
measure geometrical characteristics.
NONDESTRUCTIVE TESTING (NDT): See
NONDESTRUCTIVE EXAMINATION.
QUALIFIED ENGINEER/QUALIFIED
ENGINEERING ORGANIZATION: An
engineer or engineering organization whose
competence in evaluation of the type of
equipment in question has been demonstrated to
the satisfaction of the responsible manager.
Chapter 1
Terminology and Definitions
1-8
DOE-STD-1090-2001
QUALIFIED INSPECTOR: One whose
competence is recognized by the responsible
manager and whose qualification to perform
specific inspection activities has been
determined, verified, and attested to in writing.
1-9
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
SHALL: A word indicating that an action is
mandatory.
Chapter 1
Terminology and Definitions
1-10
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DOE-STD-1090-2001
SWITCH, MAIN: A switch controlling the
entire power supply to a crane or other
equipment, often called the disconnect switch.
1-11
Chapter 1
Terminology and Definitions
DOE-STD-1090-2001
Figure. 1-5.
Chapter 1
Terminology and Definitions
1-12
DOE-STD-1090-2001
CHAPTER 2
CRITICAL LIFTS
2-i
Chapter 2
Critical Lifts
DOE-STD-1090-2001
ix.
c.
The PIC shall ensure that a pre-job plan or
procedure is prepared that defines the operation
and includes the following:
e.
Only designated, qualified signalers shall
give signals to the operator. However, the
operator shall obey a STOP signal at all times,
no matter who gives the signal.
f.
The procedure and rigging sketches shall
be reviewed and approved by the responsible
manager (or designee) and the responsible
oversight organization (such as safety, quality
assurance, or quality control) before the lift is
made.
ii.
Load-indicating devices.
Lifting points.
v.
Sling angles.
vi.
Chapter 2
Critical Lifts
2-2
DOE-STD-1090-2001
CHAPTER 4
LIFTING PERSONNEL
4-i
Chapter 4
Lifting Personnel
DOE-STD-1090-2001
4.1 GENERAL
This chapter specifies the operation, design,
testing, and inspection requirements for the use
of personnel lift platforms or baskets suspended
from mobile or overhead cranes. This chapter
implements the requirements of 29 CFR
1926.550(g) Cranes and Derricks and ASME
B30.23, Personnel Lifting Systems.
4.1.2
Designated Leader
a.
The Authorizing Manager shall appoint a
Designated Leader for the entire personnel
lifting operation.
a.
The use of a crane to hoist employees on a
personnel lift platform is prohibited, except
when the erection, use, and dismantling of
conventional means of reaching the worksite,
such as a personnel hoist, ladder, stairway,
aerial lift, elevating work platform or scaffold,
would be more hazardous or is not possible
because of structural design or worksite
conditions.
2.
After proof-testing, any deficiencies
revealed by inspection, or by the proof test, be
corrected and another proof-test conducted.
3. Any modification to the personnel
lift platform or rigging requires retesting.
4. Test reports be kept on file and be
readily available to appointed personnel.
c.
For each personnel lifting procedure, the
manager responsible for the task shall authorize
the use of a crane-suspended work platform and
attest to the need for the operation through a
written justification attesting to that need. A
statement describing the operation and its time
frame shall be included. The statement, after
being approved by the authorizer, shall be
retained at the job site.
d.
The manager specifically responsible for
the overall work function shall not allow or
require any operator to lift personnel under the
following circumstances:
c.
The designated leader and the crane
operator shall determine that:
4-1
Chapter 4
Lifting Personnel
DOE-STD-1090-2001
blocks under outrigger floats are used as
necessary to provide a firm and substantial
footing.
Lifting Operations
4.1.4.1
Pre-Lift Meeting
a.
A meeting attended by the operator, the
ground crew, signaler(s), person(s) to be lifted,
and the designated leader shall be held each
shift to plan and review procedures to be
followed, including:
4.1.4
No interferences exist.
b.
This meeting shall be held at each new
work location, and shall be repeated for any
employees newly assigned to the operation.
4.1.3
4.1.4.2
Trial Lift
a.
Each shift, before personnel initially enter
the personnel lift platform, the operator and
signaler shall be conduct a trial lift. The trial lift
shall include:
a.
After the trial lift, prior to lifting
personnel:
1.
A visual inspection of the crane,
rigging, and personnel lift platform shall be
conducted by a qualified inspector. Any defects
found that create a safety hazard shall be
corrected prior to hoisting personnel.
4.1.4.3
Lifting Personnel
a.
Prior to hoisting personnel in a personnel
lift patform ensure that:
Chapter 4
Lifting Personnel
Pre-Lift Inspection
3.
4-2
DOE-STD-1090-2001
5. The primary attachment is centered
over the platform.
level.
3. Operate the crane so that lowering
will be power-controlled (no free-fall).
e.
Personnel lift platforms should not be used
in winds greater than 20mph (32.2 km/hr),
electric storms, snow, ice, sleet, or other adverse
weather conditions that could affect the safety
of personnel.
f.
Use tag lines to control motion of occupied
personnel lift platforms unless their use creates
an unsafe condition.
c.
Operators of cranes hoisting personnel in a
personnel lift platform shall:
4-3
Chapter 4
Lifting Personnel
DOE-STD-1090-2001
a.
Personnel are permitted to ride only in one
of the following:
i.
Pendant supported, jib type, boon
extensions without positive stops are prohibited
for personnel lifting.
e.
Cranes having booms in which lowering is
controlled by a brake without aid from other
devices which slow the lowering speeds is
prohibited.
j.
Hooks on overhaul ball assemblies, lower
load blocks, or other attachment assemblies
shall be of the type that can be closed and
locked, eliminating the hook throat opening.
(See Figure
4-1). Alternatively, an alloy anchor type
shackle with a bolt, nut and retaining pin may be
used.
f.
Crane load lines shall be capable of
supporting, without failure, at least seven times
Chapter 4
Lifting Personnel
4-4
DOE-STD-1090-2001
8.
Rough edges exposed to contact by
employees surfaced (ground smooth) to prevent
injury.
a.
The personnel lift platform and suspension
system shall be designed by a qualified person
competent in structural design and familiar with
national consensus standards governing
personnel platform design.
b. All welding of the platform shall be
performed by a qualified welder in accordance
with ANSI/AWS D1.1. Where special steels or
other materials are used, the manufacturer shall
provide welding procedures. Welds shall be
inspected by a qualified inspector
c.
4-6
DOE-STD-1090-2001
4.5 INSPECTIONS
All equipment used in the lifting of personnel
shall be inspected, tested, and maintained to
protect against failure during lifting operation.
iv.
v.
Platform flooring.
4.5.1
Frequent Inspection
vi.
4.5.1.1
General
3.
Attachment mechanisms.
i.
a.
The platform manufacturer shall furnish
complete inspection criteria for the platform
users. The criteria shall address all inspection
frequency classifications and shall cover:
4.
1.
The platform
i.
Overhead protection.
2.
Rigging components
ii.
Platform controls
3.
Fasteners
4.
4.5.1.2
c.
For frequent inspections, dated records for
the hoisting equipment and personnel lift
platform shall be made and kept by the platform
user for the duration of the personnel lift
operation.
a.
Prior to initial use and at each new job the
platform shall be inspected by a qualified
inspector in accordance with the instructions
provided by the manufacturer.
Periodic Inspection
4.5.2.1
b.
Platforms which have been out of service
for 12 or more consecutive months shall receive
a periodic inspection prior to use.
4.5.2
Platform structure:
c.
Dated inspections records for the platform
shall be made. The last periodic inspection
records shall be kept with the platform and
available for review.
i.
4.5.2.2
ii.
a.
Hoisting equipment shall be inspected in
accordance with requirements of Chapter 7,
Overhead & Gantry Cranes, or Chapter 9,
Mobile Cranes.
Chapter 4
Lifting Personnel
4-8
Hoisting Equipment
DOE-STD-1090-2001
4.7
4.7.1
General
a.
When lifting personnel near electrical
power lines, it is advisable to perform the lift so
there is not possibility of the crane, load line, or
personnel platform becoming a conductive path.
c.
Lifting personnel near electrical power
lines is not allowed unless there is no less
hazardous way to perform the job. The
following conditions must be considered when
lifting personnel near electrical power lines:
4.7.2
Condition A
a.
Power Lines are de-energized and
grounded. (The safest and preferred condition).
The following steps shall be taken when lifting
personnel in Condition A:
1. The electrical utility organization
shall de-energize the power lines.
4.7.3
Condition B
Chapter 4
Lifting Personnel
4-10
DOE-STD-1090-2001
10. Proximity warning devices, insulated
links or boom cages, if used, shall not be a
substitute for any requirements of this section.
4.7.4
Condition C
a.
Power lines are energized with the
equipment inside the prohibited zone (See Table
4-1). Lifting personnel in this condition is
strictly prohibited.
Over
Over
Over
Over
Over
50
200
350
500
750
to
to
to
to
to
to
Minimum required
clearance
50 kV
200 kV
350 kV
500 kV
750 kV
1000 kV
10 ft
15 ft
20 ft
25 ft
35 ft
45 ft
( 3.1 m)
( 4.6 m)
( 6.1 m)
( 7.6 m)
(10.7 m)
(13.7 m)
Over
0.75
Over
50
Over 345
Over 750
to
to
to
to
to
Minimum required
clearance
0.75 kV
50 kV
345 kV
700 kV
1000 kV
4-11
4 ft
6 ft
10 ft
16 ft
20 ft
(1.2 m)
(1.3 m)
(3.5 m)
(4.9 m)
(6.1 m)
Chapter 4
Lifting Personnel
DOE-STD-1090-2001
Figure 4-3 Danger Zone for Cranes and Lifting Personnel Near Electrical Transmission
Line
Chapter 4
Lifting Personnel
4-12
DOE-STD-1090-2001
4-13
Chapter 4
Lifting Personnel
DOE-STD-1090-2001
EXHIBIT I
(SAMPLE FORM)
BRIDGE, WALL, GANTRY CRANE LOAD TEST FORM
EQUIPMENT NO.
MAKE
RATED CAPACITY
DATE
1.
2.
Craftsmen shall initial and date all tests, work, and inspections completed below.
Qualified inspector shall verify all steps prior to load test.
CRANE ITEM
DEFECT OK NA NO.
CRANE ITEM
DEFECT OK NA
18 Controllers
21 Panel Wiring
22 Resistors
23 Bypass Switches
24 Limit Switches
Crane Alignment
25 Contactor (Electrical)
26 Motors
10 Bumpers/Endstops
27 Gauges
11 Brake System
28 Lighting System
12
30 Operator's Cab
14 Sheaves
31 Safety
15 Warning Devices
16 Capacity Signs
33 Structural
17 Main Disconnect
7-19
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
CHAPTER 6
PERSONNEL QUALIFICATION AND
TRAINING
6-i
Chapter 6
Personnel Qualification and Training
DOE-STD-1090-2001
6.1 GENERAL
a.
This chapter delineates the requirements
for the qualification and training of operators,
riggers, inspectors, maintenance personnel,
trainers, persons-in-charge (PIC), designated
leaders, and first-line supervisors.
6-1
Chapter 6
Personnel Qualification and Training
DOE-STD-1090-2001
6.2 QUALIFICATION
7. Have normal depth perception, field of
vision, manual dexterity, coordination, and no
tendencies to dizziness or similar potentially
hazardous characteristics.
6.2.1 General
Only qualified personnel or trainees, under the
direct supervision of qualified personnel, who
meet the following requirements shall be
allowed to rig, operate, inspect, or perform
maintenance on cranes, hoists, or powered
forklift trucks:
6.2.2 Operators of
Cab-Operated and
Pulpit-Operated Cranes
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Chapter 6
Personnel Qualification and Training
6-2
DOE-STD-1090-2001
cause for disqualification. In these cases,
medical judgments and tests may be required.
3.
Loss of stability.
4.
Control malfunction.
Maneuvering skills.
3.
Shutdown.
4.
2.
2.
Fire.
1.
1.
6-3
Chapter 6
Personnel Qualification and Training
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DOE-STD-1090-2001
c. Selection of proper equipment/tools.
6.2.5 Operators of
Floor-Operated Cranes
f.
6.2.7 Riggers
6.2.10 Inspectors
Chapter 6
Personnel Qualification and Training
Critical-lift documentation.
6-4
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DOE-STD-1090-2001
c. Crane operation by crane inspectors shall be
limited to those crane functions necessary to
perform the inspection on the crane.
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6.2.11 Instructors
1.
work.
6.
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6-5
Wiring diagrams.
Chapter 6
Personnel Qualification and Training
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DOE-STD-1090-2001
6.3 TRAINING
6.3.1 General
a. Organizations that employ personnel who
operate, rig, inspect, or perform maintenance on
equipment covered in this standard shall provide
training programs, including a means of
evaluation, to ensure that the personnel are
competent to perform the operations.
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Operating characteristics.
2.
Environmental hazardsweather.
3.
Electrical hazards.
4.
5.
6.
Lifting personnel.
7.
Inspections/tests.
8.
9.
Emergency procedures.
6.3.2 Operators of
Cab-Operated,
Pulpit-Operated, and
Floor-Operated Cranes
10. Rigging.
11. Lessons learned.
19. Two-blocking.
6-6
DOE-STD-1090-2001
22. Operating practices.
Stability.
2.
Load charts.
3.
Crane setup.
4.
Refueling.
7.
Outriggers.
8.
Operator aids.
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6-7
ii.
iii.
4.
5.
Chapter 6
Personnel Qualification and Training
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DOE-STD-1090-2001
CHAPTER 7
OVERHEAD AND GANTRY CRANES
7-i
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
7.1 GENERAL
Overhead and gantry cranes include top-running
single- or multiple-girder bridge with
top-running trolley hoists (Figure 7-1),
top-running single-girder bridge with underhung
trolley hoists (Figure 7-2), and
monorails/underhung cranes (Figure 7-3).
7.1.1
c.
Holding brakes on hoists shall be applied
automatically when power is removed.
Operator Training/
Qualification
7.1.6
7.1.2
a.
The power supply for the runway
conductors shall be controlled by a switch or
circuit-breaker located on a fixed structure,
accessible from the floor, and capable of being
locked in the OPEN position.
Rated-Load Marking
7.1.3
Modification
7.1.4
c.
On floor, remote, or pulpit-operated
cranes, an enclosed disconnect device shall be
provided in the leads from the runway
conductors. This device shall be mounted on the
bridge or footwalk near the runway collectors.
There shall be provisions for locking the device
in the OPEN position unless the crane is the
only load on a lockable switch or circuit-breaker
that is accessible from the floor. One of the
following types of floor, remote, and
pulpit-operated disconnects shall be provided.
Egress
7.1.5
Power Shutoff
Hoist Brakes
a.
Each independent hoisting unit shall be
equipped with at least one holding brake applied
directly to the motor shaft or some part of the
gear train.
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Overhead and Gantry Cranes
DOE-STD-1090-2001
Chapter 7
Overhead and Gantry Cranes
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DOE-STD-1090-2001
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Chapter 7
Overhead and Gantry Cranes
7-4
DOE-STD-1090-2001
3. A main-line contactor operated by a
switch or push button on the pendant
push-button station, the remote-control station,
or the pulpit.
7.1.7
7.1.8
Load Limits
Hoist-Limit Switch
7.1.9
a.
The hoisting motion of all cranes shall
have an overtravel-limit switch/device in the
hoisting direction to stop the hoisting motion.
Maintenance History
7-5
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
7.2 INSPECTIONS
7.2.1
General
7.2.2
Crane Service
b. Heavy serviceoperating at 85 to
100 percent of rated load or in excess of 10 lift
cycles/hr as a regular specified procedure.
c.
Severe serviceoperating at normal or
heavy service under abnormal operating
conditions (i.e., extreme temperatures, corrosive
atmospheres).
7.2.3
Initial Inspection
7.2.5
7.2.4
a.
The operator or other designated person
shall visually inspect the following items for
damage, wear, or other deficiency that might
reduce capacity or adversely effect the safety of
the crane:
Daily Preoperational
Check
1.
2.
hooks
a.
Operators or other designated personnel
shall visually inspect items such as the following
each day or prior to first use if the
Chapter 7
Overhead and Gantry Cranes
7-6
DOE-STD-1090-2001
c.. Hoist rope for significant wear, kinking,
crushing, birdcaging, and corrosion.
c.
Dated and signed inspection records shall
be kept on file and shall be readily available.
d. A sample load test form is included as
Exhibit I, which appears at the end of this
chapter. This form is intended to be a sample
only and is not intended to be mandatory.
f.
Signed and dated inspection records shall
be kept on file and shall be readily available.
g. Before the crane is returned to service,
correct deficiencies that could reduce its
capacity or adversely effect its safety.
7.2.6
7.2.7.1
Frequent Inspection
a.
Components for deformation, cracks, or
corrosion.
a.
Operators or other designated personnel
shall visually inspect the crane at the following
intervals (records are not required):
1.
Normal servicemonthly.
2.
3.
f.
Brake-system parts, linings, pawls, and
latches for excessive wear.
c.
Operators or other designated personnel
shall examine deficiencies and determine
whether a more detailed inspection is required.
7.2.7
i.
Chain-drive sprockets for excessive wear
and chains for excessive stretch.
Periodic Inspection
j.
Electrical apparatus for signs of any
deterioration of controllers, master switches,
contacts, limit switches, and push-button stations
(not limited to these items).
a.
A qualified inspector shall perform a
complete inspection at the following intervals:
1.
Normal serviceyearly.
2.
Heavy servicesemiannually.
3.
Severe servicequarterly.
e.
Parts such as pins, bearings, shafts, gears,
rollers, locking and clamping devices, bumpers,
and stops for wear, cracks, or distortion.
3.
Cranes
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Overhead and Gantry Cranes
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DOE-STD-1090-2001
7. Kinking, crushing, cutting, or
unstranding.
l.
Hook retaining nuts or collars and pins,
welds, or riveting used to secure the retaining
members for soundness.
m. Nondestructive examination of hooks and
of welds, bearings, or other suspect load-bearing
parts when required by the inspector.
c.
No precise rules can be given for
determining the exact time to replace rope
because many variables are involved. Safety in
this respect depends largely on the use of good
judgment by an appointed person in evaluating
remaining strength in a used rope, after
allowance for deterioration disclosed by
inspection. Safety of rope operation depends on
this remaining strength.
7.2.7.2
Wire Rope
a.
A qualified inspector shall inspect all ropes
at least annually. This inspection shall include
examination of the entire length of the rope,
without detaching it from the hoist drum. More
frequent intervals shall be determined by a
qualified person and shall be based on such
factors as expected rope life as determined by
experience on the particular installation or
similar installations, severity of environment,
percentage of capacity lifts, frequency rates of
operation, and exposure to shock loads. The
qualified inspector shall carefully note any
deterioration such as described below resulting
in appreciable loss of original strength and
determine whether further use of the rope
constitutes an acceptable risk.
e.
Replacement rope and connections shall
have a strength at least as great as the original
rope and connections furnished by the crane
manufacturer. Any deviation from the original
size, grade, or construction shall be specified by
a rope manufacturer, the crane manufacturer, or
a qualified person.
f.
7.2.7.3
a.
Operate the crane under load in raising and
lowering directions, and observe the operation
of the chain and sprockets. The chain should
feed smoothly into and away from the sprockets.
Chapter 7
Overhead and Gantry Cranes
7-8
DOE-STD-1090-2001
chain for powered hoists or is 2.5 percent longer
than the unused chain for hand-operated chain,
replace the chain.
Rope diameter
Maximum allowable
reduction from
Nominal diameter
Up to 5/16 in.
(8 mm)
c.
The chain should be cleaned before
inspection. Examine visually for gouges, nicks,
weld spatter, corrosion, and distorted links.
Slacken the chain and move adjacent links to
one side to inspect for wear at the contact points.
If wear is observed or stretching is suspected,
the chain should be measured according to the
hoist manufacturer's instructions. If instructions
are not available, proceed as follows:
i.
When a chain is replaced, disassemble and
inspect the mating parts (sprockets, guides,
stripper) for wear, and replace if necessary.
j.
Discarded load chain shall not be used for
slings.
7.2.7.4
Chain (Roller)
a.
Test the crane under load in raising and
lowering directions, observing the operation of
the chain and sprockets. If the chain binds,
jumps, or is noisy, clean and properly lubricate
it. If the trouble persists, inspect the chain and
mating parts for wear, distortion, or damage.
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Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
c.
Roller chain shall be replaced if any of the
conditions exist as stated
inparagraphs 7.2.7.4.b., 1 through 5 above.
d. Deficiencies as stated in
paragraph 7.2.7.4.b.6 above are reason for
questioning chain safety and considering its
replacement.
e.
Repairing of roller chain by welding or
heating shall not be attempted.
f.
Replacement chain shall be the same size,
grade, and construction as the original chain
furnished by the crane manufacturer unless
otherwise recommended by the manufacturer
due to working conditions.
ii.
7.2.8
a.
Cranes that have been idle for 1 month or
more but less than 6 months shall be inspected
before being placed in service according to the
requirements listed above in Section 7.2.6,
Frequent Inspection.
v.
Corrosion, pitting, or
discoloration.
vi.
Chapter 7
Overhead and Gantry Cranes
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DOE-STD-1090-2001
7.3 TESTING
7.3.1
Operational Tests
a.
Prior to initial use, all new, reinstalled,
repaired, or modified cranes shall be tested by a
designated person to ensure compliance with
this chapter, including the following functions:
1.
2.
Trolley travel.
3.
Bridge travel.
e.
The replacement of load chain and rope is
specifically excluded from this requirement;
however, an operational test of the crane shall be
made in accordance with para. 7.3.1.a.1 prior to
putting the crane back in service.
Limit switches/devices.
7.3.2
f.
If wire rope clips or wedge socket end
connection are installed during wire rope
installation:
1. The crane should be cycled several
times with a load equal to or greater than the
maximum operational load, normally 100percent
of the rated capacity.
a.
Prior to initial use, all new or reinstalled
cranes and cranes in which the load sustaining
parts have been altered, modified, repaired, or
replaced, or whose rated capacities have been
affected shall be tested by or under the direction
of a qualified inspector
b.
A written report confirming the rated load
testing of the crane shall be furnished by the
inspector.
c.
Test loads shall not be less than 100
percent or more than 125 percent of the rated
capacity, unless otherwise recommended by the
manufacturer or a qualified person.
i.
Test weights shall be accurate to within
-5 percent, +0 percent of stipulated values.
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Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
7.4 MAINTENANCE
7.4.1
Operating Equipment
a.
A preventive maintenance program shall
be established and based on the recommendation
of the crane manufacturer. If manufacturers
recommendations are no longer available, a
qualified person shall establish the programs
requirements. Dated records should be kept
where readily available to appointed personnel.
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Wire-Rope Maintenance
e.
Maintain rope in a well-lubricated
condition to reduce internal friction and prevent
corrosion. Ensure that lubricant applied as part
of a maintenance program is compatible with the
original lubricant and is also a type that does not
hinder visual inspection. Those sections of rope
located over sheaves or otherwise hidden during
inspection and maintenance procedures require
special attention when the rope is being
lubricated.
Chapter 7
Overhead and Gantry Cranes
7.4.2
a.
Store rope to prevent damage or
deterioration.
c.
All moving parts of the crane for which
lubrication is specified shall be regularly
lubricated. Check lubricating systems for
delivery of lubricant. Follow manufacturer's
recommendations as to points and frequency of
lubrication, maintenance of lubricant levels, and
types of lubricant to be used.
4.
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DOE-STD-1090-2001
7.5 OPERATION
a.
The following shall apply to all personnel
involved in overhead and gantry crane
operation.
7.5.1
j.
l.
Lock and tag the main positive electrical
control switch in the OPEN position before any
crane maintenance is performed.
Conduct of Operator
a.
Do not engage in any practice that will
divert your attention while operating the crane.
c.
Operators shall be held directly responsible
for the safe operation of their equipment.
Whenever there is any question as to the safety
of the activity, an operator has the authority to
stop and refuse to handle loads until the matter
has been resolved by supervisory personnel.
7.5.2
e.
If you find the crane's main or emergency
switch open when starting on duty, do not close
it until it has been determined that no one is on
or close to the crane. If there is a warning sign
on the switch, do not remove it unless you
placed it there. Do not close the switch until the
warning sign has been removed by the person
who placed it there.
Hoist-Limit
Switch/Device
a.
At the beginning of each work shift, or the
first time the crane is used during a shift, test the
upper-limit switch/device of each hoist under no
load. Exercise extreme care to avoid
two-blocking; inch the block into the limit
switch or run it in at slow speed. If the
switch/device does not operate properly,
immediately notify the supervisor.
f.
Before closing the main switch, ensure that
all controllers are in the OFF position.
c.
Do not use the final hoist-limit switch/
device that controls the upper limit of travel of
the load block as an operating control.
7.5.3
i.
Contacts with runway stops or other cranes
shall be made with extreme caution. If you are
ordered to engage with or push other cranes, do
this with particular care for the safety of persons
on or below the cranes, and only after making
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Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
MAGNET IS DISCONNECTED.
Crane operator spreads both hands
apart, palms up.
Figure 7-4. Standard hand signals for controlling overhead crane operation.
Chapter 7
Overhead and Gantry Cranes
7-14
DOE-STD-1090-2001
7.5.4
Identification of
Signalers
7.5.7
a.
The person appointed to direct the lift shall
see that the load is well secured and properly
balanced in the sling or lifting device before it is
lifted more than a few inches.
a.
All personnel acting as signalers during
crane operations shall be clearly identified to the
crane operator by using the following (one or
more, as required by the responsible manager):
orange hardhat, orange gloves, and orange vest.
This requirement may be waived by the
responsible manager when the lift is very closely
controlled or personnel are required to wear
special clothing for protection from a hazardous
environment.
c.
Where voice (direct or two-way radio)
communication is used, the signaler shall
communicate directly with the operator, not
through a third person.
Size of Load
a.
The weight of the load shall be determined
prior to making the lift.
7.5.6
7.5.5
a.
Ensure that the hoist rope is free from
kinks or twists. Do not wrap the hoist rope
around the load.
b. Ensure the load is attached to the
load-block hook by means of slings or other
approved devices.
e.
f.
Each time a load approaching the rated
capacity is handled, test the hoist brakes by
raising the load a few inches and applying the
brakes. Any slippage or downward motion is
unacceptable.
c.
Take care to make certain that the sling
clears all obstacles.
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Chapter 7
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DOE-STD-1090-2001
e.
The designated leader's responsibility shall
include the following:
i.
Tag lines should be used as required to
guide, snub, or otherwise control the load.
j.
Place any attached load on the ground or
floor, place controls in the OFF position, and
turn off the power source before leaving the
crane unattended, unless required to do
otherwise by an approved emergency procedure.
7.5.8
Ordinary Lifts
a.
The requirements of all preceding
paragraphs in Section 7.5, Operation, also
shall apply to ordinary lifts.
f.
The operator, or a designated person, shall
ensure that the crane is still within the inspection
interval.
c.
Hoisting and rigging operations for
ordinary lifts require a designated leader who
shall be present at the lift site during the entire
lifting operation. If the lift is being made by
only one person, that person assumes all
responsibilities of the designated leader.
7.5.9
Chapter 7
Overhead and Gantry Cranes
Critical Lifts
7-16
DOE-STD-1090-2001
7-17
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
EXHIBIT I
(SAMPLE FORM)
Page 1 of 4
MAKE
RATED CAPACITY
DATE
1.
2.
Craftsmen shall initial and date all tests, work, and inspections completed below.
Qualified inspector shall verify all steps prior to load test.
CRANE ITEM
DEFECT OK NA NO.
CRANE ITEM
DEFECT OK NA
18 Controllers
21 Panel Wiring
22 Resistors
23 Bypass Switches
24 Limit Switches
Crane Alignment
25 Contactor (Electrical)
26 Motors
10 Bumpers/Endstops
27 Gauges
11 Brake System
28 Lighting System
12
30 Operator's Cab
14 Sheaves
31 Safety
15 Warning Devices
16 Capacity Signs
33 Structural
17 Main Disconnect
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Chapter 7
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DOE-STD-1090-2001
EXHIBIT I (continued)
Page 2 of 4
1.
2.
3.
Load test shall be performed on all new, repaired, or modified cranes prior to initial use.
4.
Load test crane at 125% of rated capacity. In no case shall the load test exceed 125% of rated
capacity. Test weights shall be accurate to -5%, + 0% of stipulated values.
INITIAL
1.
Set crane up for load test and qualified inspector verify inspection is complete prior to load
test.
2.
The trip setting of hoist-limit devices shall be determined by tests, with an empty hook
traveling at increasing speeds up to the maximum speed. The actuating mechanism of the
limit device shall be located so that it will trip the device under all conditions and in
sufficient time to prevent contact of the hook or load block with any part of the trolley or
crane.
3.
4.
Hoist the test load a sufficient distance to ensure that the load is supported by the crane and
held by the hoist brakes.
5.
Transport the test load by means of the trolley for the full length of the bridge. Ensure
during operation that the trolley runs true on the bridge. Check trolley motor, brake, and
gear case for overheating.
6.
Transport the test load by means of the bridge for the full length of the runway, first in one
direction with the trolley as close to the extreme right-hand end of the crane as practical and
next in the other direction with the trolley as close to the extreme left-hand end of the crane
as practical. Ensure that the bridge runs true on the runway rails and that no undue girder
deflection occurs. Check for bridge motor, brake, and gear-case overheating.
7.
Move the test load back into the original position and lower the test load, stopping by the
brakes. Hold the load for 10 min or the time required to check all primary load-bearing parts
while under load for slippage, damage, or permanent deformation.
8.
9.
At the completion of the load test, visually inspect the following load-bearing parts for signs
of wear, deformation, and deterioration:
Chapter 7
Overhead and Gantry Cranes
7-20
DOE-STD-1090-2001
EXHIBIT I (continued)
Page 3 of 4
DEFECTIVE/OK/NA
a.
Bridge track
b.
Bridge wheels
c.
Trolley track
d.
Trolley wheels
e.
Gears
f.
Magnetic brakes
g.
Blocks.
Visually inspect rope in accordance with Chapter 11, Wire Rope and Slings.
a.
b.
Wear
c.
Kinks
d.
Broken wires
e.
(Present)
Wear
b.
Deformation
c.
Deterioration.
INITIAL
10. Qualified inspector shall perform nondestructive tests on hook by visual examination, liquid
penetrant examination, or magnetic-particle examination. Acceptance: No cracks, linear
indications, laps, or seams.
Hooks with more than 15% normal (new hook) throat opening shall be replaced. Hooks with more than 10 degree
twist from the normal (new hook) plane of the hook shall be replaced. Hooks having more than 10% wear in the
throat section or 5% elongation of the shank shall be replaced. Lubricate hook bearing and latch pin as applicable.
Establish three marks, A, B, and C, with a center punch. For ease in measuring, set distances on an even number of
inches.
7-21
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
EXHIBIT I (continued)
BEFORE LOAD TEST
Length AB
in.
Length BC
in.
in.
Length BC
in.
Check for:
1. Wear and deformation
2. Cracks and twisting
3. Signs of opening between Point A and Point B
Load Test Inspection Date
Qualified Inspector
Operated By
Actual Load Test
Chapter 7
Overhead and Gantry Cranes
lb
7-22
Page 4 of 4
DOE-STD-1090-2001
EXHIBIT I I
(SAMPLE FORM)
Page 1 of 2
CAPACITY
OPERATORS NAME:
1.
TYPE
LOCATION
SHIFT
12 3
WALK AROUND
INSPECTION
S /U/
NA
2.
MACHINERY
INSPECTION
S/U/
NA
a Foundations
Holding Brake
b Access
c Secured Items
Covers Secured
d Walkways/Handrails
Upper Sheaves
Wire Rope
g Hydraulics
Fluid Leaks
h Couplers/Connection Rods
Batteries
Electric Motors
j Rail Sweeps
Electric Panels
k Windlocks/Chock/Stops
Runway/Bridge Conductors
l Housekeeping
Runway/Bridge Collectors
f Bridge Brake
i End Trucks
m Electrical Guards
n
Festoon System
Warning Tags/Signs
Trolley Stops
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Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
EXHIBIT II (continued)
Page 2 of 2
OPERATOR CAB
INSPECTION
S/U/
NA
a Housekeeping
4.
OPERATION
INSPECTION
S/U/
NA
Manual Reset
c Cab Door(s)
Stop Button/Control
d Fire Extinguisher
Pendant Buttons
e Controls Identification
Upper Limit/Main
f Electrical Enclosures
Upper Limit/Auxiliary
Lower Limit/Main
h Visibility/Windows
Lower Limit/Auxiliary
i Safety Devices
Bridge Controls
j Warning/Indicator Light
Bridge Brake
k Alarms
Trolley Control
Main Hook
m Auxiliary Hook
b Warning Tags
Work Area
Runway Stops
INSTRUCTIONS: Inspect all applicable items each shift of operation. Suspend all operations
immediately when observing an unsatisfactory condition for asterisked (*) items. In addition, suspend
operation when any unsafe condition is observed and immediately notify supervisor. Other conditions
not affecting safety shall be noted under Remarks and reported to supervisor.
REMARKS:
Chapter 7
Overhead and Gantry Cranes
7-24
DOE-STD-1090-2001
EXHIBIT III
(SAMPLE FORM)
Page 1 of 2
CAPACITY:
STATUS CODE:
LOCATION:
ITEM
OK
CODE
ITEM
OK
Bridge
- Cam Followers/Guide*
- Alignment
- Runway End-Stops
- Girders (camber)
- Railway Sweeps /
Safety Lugs
- Rails
- Energy Absorbing
Bumpers
- Walks, Ladders,
Railings
Mono Rail
- Trucks to Girder
Connection
- Girders
- Trucks
- Girder Supports
- Wheels, Driver *
- Sway Braces
- Wheels, Idler *
Misc.
- Wheels, Bearings *
- Clearances
Overhead (3")
- Squaring Shaft
- Squaring Shaft
Couplings
- Each Hoist/Load
Block
- Motor Coupling *
Trolley Drive
- Gear Reducer
- Wheels, Driver *
- Wheels, Idler *
- Axle Pinion
- Wheels Bearings *
- Axle Gear
- Runway Alignment
- Motor Couplings *
7-25
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Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
EXHIBIT III (continued)
(SAMPLE FORM)
ITEM
OK
CODE
ITEM
- Gear Reducer
- Drum Grooving
- Drum Shafts
- Axle Pinion
- Motor Pinion
- Axle Gear
- Motor Gear
- Cam Followers/Guides
*
- Intermediate Pinion
- Energy Absorbing
Bumpers
- Intermediate Gear
- End Stops
- Drum Pinion
Hoist (M - Main)
(A - Auxiliary)
- Drum Gear
- Hook
- Hook Bearing
- Mechanical Load
Brake*
- Sheaves *
- Fricton Disc*
- Sheave Bearings *
- Pawl *
- Equalizer Sheave *
- Pawl Shifter
- Rope/Chain
- Ratchet or Band
- Rope Anchors
- Motor Coupling *
Page 2 of 2
OK
CODE
Notes:
Circle One:
PASS
INSPECTOR (print):
FAIL
SIGNATURE:
DATE:
Items with * to be inspected prior to use as part of the Pre-Operational check and lubricated as needed. All
other items to be inspected and lubricated annually.
Chapter 7
Overhead and Gantry Cranes
7-26
DOE-STD-1090-2001
EXHIBIT IV
(SAMPLE FORM)
Page 1 of 2
CAPACITY:
STATUS CODE:
LOCATION:
ITEM
OK
CODE
ITEM
Brakes
Misc
OK
CODE
Controls
- Master Switches
- Hydraulic Brake
Bleeder *
- Push-button Station
Motors
- M.H. Contactors
- A.H. Contactors
- Trolley Contactors
- Bridge Contactors
7-27
Chapter 7
Overhead and Gantry Cranes
DOE-STD-1090-2001
EXHIBIT IV (continued)
(SAMPLE FORM)
ITEM
OK
CODE
ITEM
Controls (continued)
Resistors
- Trolley Overhead
Relays
- M.H. Resistors
- A.H. Resistors
- Trolley Resistors
- Bridge Resistors
Mainline
- Mainline Switch
- M.H. Segments *
- Fuses (Sizes
................)
- Power Wiring
- A.H. Segments *
- Control Wiring
- Trolley Collectors *
- Trolley Segments *
- Runway Collectors *
- Bridge Conductors
- Bridge Segments *
- Runway Conductors
Page 2 of 2
OK
CODE
Notes:
Circle One:
PASS
INSPECTOR (Print):
FAIL
SIGNATURE:
DATE:
Items with * to be inspected prior to use as part of the Pre-operational check and lubricated as needed.
All other items to be inspected and adjusted annually.
Chapter 7
Overhead and Gantry Cranes
7-28
DOE-STD-1090-2001
CHAPTER 9
MOBILE CRANES
9-i
Chapter 9
Mobile Cranes
DOE-STD-1090-2001
9.2 INSPECTIONS
9.2.1
General
9.2.4
9.2.2
Monthly Inspection
a.
The operator or other designated person
shall visually inspect the following items for
damage, wear, or other deficiency that might
reduce capacity or adversely effect the safety of
the crane:
1. Critical items such as brakes and
crane hooks.
2.
Initial Inspection
Hoist ropes.
9.2.3
c.
Hooks for cracks, deformation, damage
from chemicals, latch engagement (if provided),
and evidence of heat damage.
Daily Preoperational
Check
a.
Operators or other designated personnel
shall visually inspect items such as the
following each day or prior to use if the crane
has not been in regular service (records are not
required):
e.
Signed and dated inspection records shall
be kept on file and shall be readily available.
f.
Before the crane is returned to service,
correct deficiencies that could reduce its
capacity or adversely effect its safety.
9.2.5
a.
Operators or other designated personnel
shall visually inspect the crane at daily to
monthly intervals (records are not required).
level.
4. Lines, tanks, valves, pumps, and
other parts of air or hydraulic systems for
leakage.
2.
Chapter 9
Mobile Cranes
Frequent Inspection
9-6
DOE-STD-1090-2001
5. Tires for recommended inflation
pressure.
c.
Operators or other designated personnel
shall examine deficiencies and determine
whether a more detailed inspection is required.
9.2.6
i.
Gasoline, diesel, electrical, or other power
plants for improper performance or
noncompliance with safety requirements.
Periodic Inspection
j.
Radiators and oil coolers, for leakage,
improper performance, or blockage of air
passages.
a.
Complete inspections of the crane shall be
performed by a qualified inspector at 1- to
12-month intervals, depending on the crane's
activity, severity of service, and environment.
l.
Steering, braking, and locking devices, for
malfunctioning.
m.
c.
Dated and signed inspection records shall
be kept on file and shall be readily available.
9.2.6.2
a.
Evidence of leakage at the surface of the
flexible hose or its junction with the metal
couplings.
Cranes
Inspect for:
a.
Deformed, cracked, or corroded members
in the crane structure and entire boom.
c.
Leakage at threaded or clamped joints that
cannot be eliminated by normal tightening or
recommended procedures.
Inspect for:
e.
These inspections shall, in addition to the
requirements of Sections 9.2.4 , Monthly
Inspection, and 9.2.5, Frequent Inspection,
include the following.
9.2.6.1
|
|
e.
Hooks damaged from chemicals,
deformation, or cracks, or having more than 15
percent in excess of normal throat opening or
more than 10 degree twist from the plane of the
unbent hook (dye-penetrant, magnetic-particle,
or other suitable crack-detecting inspections
should be performed at least once a year; see
Chapter 13, Load Hooks, for additional hook
requirements).
Inspect for:
f.
Worn, cracked, or distorted parts such as
pins, bearings, shafts, gears, rollers, and locking
devices.
9-7
a.
b.
c.
d.
DOE-STD-1090-2001
e.
f.
g.
Loss of pressure.
9.2.6.4
Inspect for:
a.
d.
Sticking spools.
e.
Failure of relief valves to attain correct
pressure setting (relief valve pressures shall be
checked as specified by the manufacturer).
Inspect for:
a.
Drifting caused by fluid leaking across the
piston.
b.
c.
d.
e.
9.2.6.5
f.
Loose or deformed rod eyes or connecting
joints.
9.2.6.6
Hydraulic Filters
Wire Rope
a.
A qualified inspector shall inspect wire
ropes at least annually. More frequent intervals
shall be determined by a qualified person and
shall be based on such factors as expected rope
life as determined by severity of environment,
percentage of capacity lifts, frequency rates of
Chapter 9
Mobile Cranes
9-8
DOE-STD-1090-2001
c.
The qualified inspector shall take care
when inspecting certain ropes such as the
following:
e.
Conditions such as the following shall be
sufficient reason for questioning wire-rope
safety and for considering replacement:
i.
9.2.7
Load Hooks/Load
Blocks
9.2.8
a.
A crane that has been idle for 1 month or
more but less than 6 months shall be given an
inspection according to the requirements of
Section 9.2.5 before being placed in service.
c.
Standby cranes shall be inspected at least
semiannually, according to the requirements of
Section 9.2.6. Cranes exposed to adverse
environments should be inspected more
frequently.
9-9
Chapter 9
Mobile Cranes
DOE-STD-1090-2001
9.3 TESTING
9.3.1
Operational Tests
b.
c.
Boom extension and retraction
mechanism.
d.
Swinging mechanism.
e.
Travel mechanism.
f.
Safety devices.
9.3.2
c.
A written report shall be furnished by the
inspector showing test procedures and
confirming the adequacy of repairs or
alterations. Test reports shall be kept on file
and shall be readily available to appointed
personnel.
a.
Prior to initial use, all cranes in which
load-sustaining parts have been modified,
replaced, or repaired shall be load-tested by a
qualified inspector or under the direction of that
inspector. A designated or authorized
Chapter 9
Mobile Cranes
9-10
DOE-STD-1090-2001
EXHIBIT I
(SAMPLE FORM)
Page 1 of 4
MAKE
DATE
RATED CAPACITY
1.
2.
CRANE ITEM
DEFECT OK NA NO.
CRANE ITEM
Wire Rope
Cracked or Worn
Sheaves & Drums
14 Hoist
Drum
Bands
Limit Switch
(Anti-Two-Blocking)
15 Open Gears
Boom
16 Boom Jibs
(Where Applicable)
Master Clutch
Steering Clutches
Hydraulic Pump
Brakes
(Service and Hand)
Hydraulic Controls
Hydraulic Hoses
General Lubrication
DEFECT OK NA
Brake
10 Mechanical Controls
OPERATING TEST
11 Drive Chains
OVERALL CONDITION
DEFECT OK NA
12 Swing Clutches
REMARKS (Unusual conditionsnoises, structural cracks, misalignment, etc.)
9-29
Chapter 9
Mobile Cranes
DOE-STD-1090-2001
CHAPTER 10
FORKLIFT TRUCKS
10-i
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
10-1 GENERAL
by Underwriters Laboratories, Inc., and Factory
Mutual Research Corporation.
f.
Batteries for use in electric trucks shall
have the battery weight legibly stamped on the
battery tray near the lifting means as follows:
Service Weight _____lb(kg).
10.1.1
Operator Training/
Qualification
10.1.2
10.1.4
Rated Capacity
10.1.3
Nameplate(s) and
Marking
b.
Weight of truck.
c.
Rated capacity.
Attachments
b
On every removable attachment (excluding
fork extensions), a corrosion-resistant nameplate
with the following information is required:
1.
Model number
2.
Serial number on hydraulically
actuated attachments
3.
Maximum hydraulic pressure (on
hydraulically actuated attachments)
10-1
4.
Weight
5.
Capacity
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
1.
Vertical movement of the lifting
mechanism is restricted to 72 in. (1800 mm) or
less from the ground.
6.
The following instructions (or
equivalent); "Capacity of truck and attachment
combination may be less than capacity shown on
attachment. Consult truck nameplate."
2.
The truck will be operated only in
an area where:
10.1.5
i.
Modifications
10.1.6
Warning Devices
10.1.8
10.1.9
10.1.7
Overhead Guards
Work Atmosphere
Chapter 10
Forklift Trucks
10-2
DOE-STD-1090-2001
Figure 10-3. Types of Trucks. (Sheet 1 of 6)
10-3
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
Chapter 10
Forklift Trucks
10-4
DOE-STD-1090-2001
10-5
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
Chapter 10
Forklift Trucks
10-6
DOE-STD-1090-2001
Figure 10-3. Types of Trucks. (sheet 5 of 6)
10-7
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
Chapter 10
Forklift Trucks
10-8
DOE-STD-1090-2001
Figure 10-4. Manually Operated Pallet Trucks
GA99 0028
GA99 0029
10-9
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
10.2.1.2
Type Designation
Non-Hazardous Areas
Chapter 10
Forklift Trucks
Hazardous Areas
10-10
DOE-STD-1090-2001
f.
Type GS Forklifts gasoline-powered
units that, in addition to all the requirements for
the type G units, are provided with additional
safeguards to the exhaust, fuel, and electrical
systems
10.2.2
10-11
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
Chapter 10
Forklift Trucks
10-12
DOE-STD-1090-2001
10-13
Chapter 10
Forklift Trucks
DOE-STD-1090-2001
CHAPTER 11
WIRE ROPE AND SLINGS
11-i
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
1.
Fiber Core (FC) or Sisal Core
Sisalanna is the most common fiber that is used
in the manufacture of wire-rope cores. In
smaller ropes, cotton and jute are sometimes
used for the core.
2.
Independent Wire-Rope Core
(IWRC)The primary function of the core is to
provide adequate support for the strands. As the
name implies, an IWRC is a separate
small-diameter wire rope that is used as the core
for a larger wire rope. When severe crushing or
flattening of the rope is encountered, an IWRC
is usually specified.
Chapter 11
Wire Rope and Slings
11-4
DOE-STD-1090-2001
1.
6 37 2-operationA 6 37
2-operation strand has 18 outer wires. This
construction is used on industrial equipment, for
flexible slings, and in miscellaneous hoisting.
2.
6 29FA 6 29F is used for
applications requiring a flexible rope slightly
more resistant to wear than the 6 37
2-operation rope.
11.2.3.1 6 19 Classification
a. Most applications can use a rope from this
classification; it is the most versatile of all ropes
made. Figure 11-4 shows four varieties of 6
19 wire ropes with FCs and IWRCs. Table 11-2
provides breaking strengths for 6 19 wire
ropes with FC and IWRC cores.
3.
6 41A 6 41 rope is used widely
for ropes over 1-in. diameter in the 6 37
classification.
1.
6 19FThe most popular and
versatile of all wire ropes and the most flexible
is the 6 19F classification. This rope is
considered the perfect compromise between
maximum abrasion resistance and maximum
flexibility.
2.
6 16FSlightly more abrasion
resistant than the 6 19F, the 6 16F makes an
excellent rope for small draglines and similar
uses. The resistance to wear is gained by a
slight sacrifice in flexibility.
3.
6 19 SealeThe 6 19 Seale is a
rugged wire rope for applications involving
heavy wear. Car pullers often use this rope, and
it is widely used for slushers and drag scrapers.
4.
6 19 WarringtonThe alternating
large and small outer wires make this rope an
all-around performer. The 6 19 Warrington is
used for general-purpose hoisting, churn drills,
and miscellaneous slings.
11.2.3.2 6 37 Classification
a. When sheaves and drums are fairly small
and abrasive conditions are not severe, the ropes
in this classification will show better
performance than the coarser 6 19
construction. Under conditions of repeated
bending, they will outlast a 6 19 rope; when
abrasion is severe, the small outer wires quickly
show the effect. Figure 11-5 shows three
varieties of 6 37 wire rope with FC and IWRC
cores. Table 11-3 provides breaking strengths
for 6 37 wire ropes with FC and IWRC cores.
11-5
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1
1 5/8
1 3/4
1 7/8
2
2 1/4
2
2 3/4
Weight
(lb per ft)
0.06
0.10
0.16
0.23
0.31
0.40
0.51
0.63
0.90
1.23
1.60
2.03
2.50
3.03
3.60
4.23
4.90
5.63
6.40
8.10
10.00
12.10
Chapter 11
Wire Rope and Slings
6 19 (IWRC)
Breaking strength
in tons of 2,000 lb
Improved
Plow steel
plow steel
1.3
1.5
2.4
2.7
3.8
4.1
5.4
6.0
7.0
8.0
10.0
11.0
11.7
13.3
15.0
16.5
21.5
23.8
28.3
32.0
38.0
41.7
48.5
53.0
60.0
65.0
73.5
81.0
88.5
96.0
103.0
113.0
119.0
130.0
138.0
152.0
154.0
169.0
193.0
210.0
235.0
260.0
280.0
305.0
11-6
Rope
diameter
(in.)
3/16
1/4
5/16
3/8
7/16
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1
1 5/8
1 3/4
1 7/8
2
2 1/4
2
2 3/4
Weight
(lb per ft)
0.07
0.11
0.18
0.25
0.34
0.44
0.56
0.69
0.99
1.35
1.76
2.23
2.75
3.33
3.96
4.65
5.39
6.19
7.04
8.91
11.00
13.30
Breaking strength
in tons of 2,000 lb
Improved
Plow steel
plow steel
1.4
1.6
2.6
2.9
4.1
4.4
5.8
6.5
7.5
8.6
10.8
11.8
12.6
14.3
16.1
17.7
23.1
25.6
30.4
34.4
40.8
44.8
52.1
57.0
64.5
70.4
79.0
87.1
95.1
103.0
111.0
122.0
128.0
140.0
148.0
163.0
166.0
182.0
208.0
226.0
253.0
280.0
301.0
328.0
DOE-STD-1090-2001
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1
1 5/8
1 3/4
1 7/8
2
2 1/4
2
2 3/4
3
Weight
(lb per ft)
0.10
0.16
0.22
0.30
0.39
0.49
0.61
0.87
1.19
1.55
1.96
2.42
2.93
3.49
4.09
4.75
5.45
6.20
7.85
9.69
11.72
13.95
6 37 (IWRC)
Breaking strength
in tons of 2,000 lb
Improved
Plow steel
plow steel
2.2
2.5
3.8
4.0
5.0
5.5
6.9
7.5
9.2
10.0
11.4
12.5
14.5
16.0
20.2
22.2
27.5
30.2
36.0
39.5
44.0
49.0
55.0
61.0
68.5
74.5
82.0
90.0
96.5
105.5
110.0
121.0
129.0
142.0
142.0
155.0
182.0
201.0
225.0
245.0
269.0
293.0
323.0
353.0
11-7
Rope
diameter
(in.)
1/4
5/16
3/8
7/16
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1
1 5/8
1 3/4
1 7/8
2
2 1/4
2
2 3/4
3
Weight
(lb per ft)
0.11
0.18
0.24
0.33
0.43
0.54
0.67
0.96
1.30
1.71
2.16
2.66
3.22
3.84
4.50
5.23
6.00
6.82
8.64
10.66
12.89
15.35
Breaking strength
in tons of 2,000 lb
Improved
Plow steel
plow steel
2.4
2.7
4.1
4.3
5.4
5.9
7.4
8.1
9.9
10.8
12.3
13.4
15.6
17.2
21.7
23.9
29.6
32.5
38.7
42.5
47.3
52.7
59.1
65.6
73.6
80.1
88.1
96.7
104.0
113.0
118.0
130.0
139.0
153.0
153.0
167.0
196.0
216.0
242.0
263.0
289.0
315.0
347.0
379.0
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
11.3 SLINGS
11.3.1 General
1.
Nominal breaking strength of
material from which it is constructed.
2.
Splicing or end-attachment
efficiency.
3.
6.
Diameter of curvature around which
the sling is bent.
3.
Chapter 11
Wire Rope and Slings
2.
4.
1.414.
4.
Type of hitch (e.g., straight pull,
choker hitch, or basket hitch).
5.
gravity.
1.
|
|
11-8
DOE-STD-1090-2001
11-9
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
11.3.1.3 Design Factor
2.
Two-leg bridle slings with
single-rope legs, equalizing double-rope legs, or
multiple-part rope legs.
4.
5.
Chapter 11
Wire Rope and Slings
3.
11-10
DOE-STD-1090-2001
11-11
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two legs
Dia. in inches
1/4
1,100
820
2,200
1,800
1,500
1,100
1/4
5/16
1,600
1,280
3.200
2,800
2,200
1,600
5/16
3/8
2,400
1,840
4,800
4,000
3,200
2,400
3/8
7/16
3,000
2,400
6,000
5,400
4,400
3,000
7/16
4,000
3,200
8,000
6,800
5,600
4,000
9/16
5,000
4,000
10,000
8,600
7,000
5,000
9/16
5/8
6,000
5,000
12,000
10,400
8,400
6,000
5/8
3/4
8,400
7,200
16,800
14,600
11,800
8,400
3/4
7/8
11,000
9,600
22,000
19,200
15,600
11,000
7/8
14,000
12,600
28,000
24,000
20,000
14,000
1 1/8
18,000
15,800
36,000
32,000
26,000
18,000
1 1/8
*1 1/4
22,000
19,400
44,000
36,000
30,000
22,000
*1 1/4
*1 3/8
26,000
24,000
52,000
44,000
36,000
26,000
*1 3/8
*1
32,000
28,000
64,000
52,000
42,000
32,000
*1
*1 5/8
36,000
32,000
72,000
62,000
50,000
36,000
*1 5/8
*1 3/4
42,000
38,000
84,000
70,000
58,000
42,000
*1 3/4
*2
56,000
48,000
112,000
92,000
74,000
56,000
*2
Notes:
(1)
These values only apply when the D/d ratio is 25 or greater (choker and basket hitches)
D = Diameter of curvature around which the body of the sling is bent
d = Diameter of rope
(2)
Choker hitch values apply only to choke angles greater than 120 degrees.
Chapter 11
Wire Rope and Slings
11-12
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two legs
Dia. in inches
1/4
980
760
1,960
1,700
1,400
980
1/4
5/16
1,500
1,200
3,040
2,600
2,200
1,500
5/16
3/8
2,200
1,700
4,400
3,600
3,000
2,200
3/8
7/16
2,800
2,400
5,600
5,000
4,000
2,800
7/16
3,600
3,000
7,200
6,400
5,200
3,600
9/16
4,600
3,800
9,200
8,000
6,400
4,600
9/16
5/8
5,600
4,600
11,200
9,600
8,000
5,600
5/8
3/4
7,800
6,600
15,600
13,600
11,000
7,800
3/4
7/8
10,400
9,000
20,800
17,800
14,600
10,400
7/8
13,400
11,800
26,800
22,000
18,800
13,400
1 1/8
16,800
14,800
33,600
28,000
24,000
16,800
1 1/8
*1 1/4
20,000
18,000
40,000
34,000
28,000
20,000
*1 1/4
*1 3/8
24,000
22,000
48,000
42,000
34,000
24,000
*1 3/8
*1
30,000
26,000
60,000
52,000
42,000
30,000
*1
*1 5/8
34,000
30,000
68,000
58,000
48,000
34,000
*1 5/8
*1 3/4
40,000
34,000
80,000
70,000
56,000
40,000
*1 3/4
*2
52,000
44,000
104,000
90,000
74,000
52,000
*2
These values only apply when the D/d ratio is 25 or greater (choker and basket hitches)
D = Diameter of curvature around which the body of the sling is bent
d = Diameter of rope
(2)
Choker hitch values apply only to choke angles greater than 120 degrees.
11-13
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two legs
Dia. in inches
1/4
1,100
840
2,200
1,940
1,580
1,100
1/4
5/16
1,700
1,300
3,400
3,000
2,400
1,700
5/16
3/8
2,400
1,860
4,800
4,200
3,600
2,400
3/8
7/16
3,400
2,500
3,800
5,800
4,800
3,400
7/16
4,400
3,200
8,800
7,600
6,200
4,400
9/16
5,500
4,200
11,000
9,600
7,700
5,500
9/16
5/8
6,800
5,000
13,600
11,800
9,600
6,800
5/8
3/4
9,700
7,200
19,400
16,800
13,600
9,700
3/4
7/8
13,000
9,800
26,000
22,000
18,300
13,000
7/8
17,000
12,800
34,000
30,000
24,000
17,000
1 1/8
20,000
15,600
40,000
36,000
30,000
20,000
1 1/8
*1 1/4
25,000
18,400
50,000
42,000
34,000
25,000
*1 1/4
*1 3/8
30,000
24,000
60,000
52,000
42,000
30,000
*1 3/8
*1
36,000
28,000
72,000
64,000
50,000
32,000
*1
*1 5/8
42,000
32,000
84,000
70,000
58,000
42,000
*1 5/8
*1 3/4
50,000
38,000
100,000
82,000
66,000
50,000
*1 3/4
*2
64,000
48,000
128,000
106,000
86,000
64,000
*2
These values only apply when the D/d ratio is 25 or greater (choker and basket hitches)
D = Diameter of curvature around which the body of the sling is bent
d = Diameter of rope
(2)
Choker hitch values apply only to choke angles greater than 120 degrees.
Chapter 11
Wire Rope and Slings
11-14
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two legs
Dia. in inches
*1/8
1,900
1,400
3,200
2,600
1,900
*1/8
*3/16
4,200
3,000
7,200
5,800
4,200
*3/16
3/16
3,400
2,600
6,000
4,800
3,400
3/16
1/4
6,200
4,600
10,600
8,600
6,200
1/4
5/16
9,600
7,200
16,600
13,400
9,600
5/16
3/8
13,600
10,200
24,000
19,400
13,600
3/8
7/16
18,000
13,800
32,000
26,000
18,600
7/16
24,000
18,000
42,000
34,000
24,000
9/16
30,000
22,000
52,000
42,000
30,000
9/16
5/8
38,000
28,000
64,000
52,000
38,000
5/8
3/4
54,000
40,000
92,000
76,000
54,000
3/4
7/8
72,000
54,000
124,000
102,000
72,000
7/8
94,000
70,000
162,000
132,000
94,000
These values only apply when the D/d ratio is 25 or greater (choker and basket hitches)
D = Diameter of curvature around which the body of the sling is bent
d = Diameter of rope
(2)
Choker hitch values apply only to choke angles greater than 120 degrees.
11-15
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two leg
60 degrees
45 degrees
30 degrees
Dia. in inches
*3/8
2,600
1,900
5,000
4,400
3,600
2,600
*3/8
*9/16
5,600
4,200
11,200
9,800
8,000
5,600
*9/16
*5/8
7,800
6,000
15,800
13,600
11,200
6,800
*5/8
3/4
10,200
7,600
20,000
17,600
14,400
10,200
3/4
15/16
15,800
11,800
32,000
28,000
22,000
15,800
15/16
1 1/8
22,000
16,800
44,000
38,000
32,000
22,000
1 1/8
1 5/16
30,000
22,000
60,000
52,000
42,000
30,000
1 5/16
38,000
28,000
78,000
66,000
54,000
38,000
1 11/16
48,000
36,000
98,000
84,000
68,000
48,000
1 11/16
1 7/8
60,000
44,000
120,000
104,000
84,000
60,000
1 7/8
2 1/4
84,000
62,000
168,000
146,000
118,000
84,000
2 1/4
2 5/8
112,000
84,000
224,000
194,000
158,000
112,000
2 5/8
144,000
108,000
286,000
248,000
202,000
144,000
These values only apply when the D/d ratio is 10 or greater (choker and basket hitches)
D = Diameter of curvature around which the body of the sling is bent
d = Diameter of rope
(2)
Choker hitch values apply only to choke angles greater than 120 degrees.
Chapter 11
Wire Rope and Slings
11-16
DOE-STD-1090-2001
Dia. in inches
Vertical
Choker
Basket or
two leg
60 degrees
45 degrees
30 degrees
Dia. in inches
1/4
1,840
1,320
3,600
3,200
2,600
1,840
1/4
3/8
4,000
3,000
8,000
7,000
5,800
4,000
3/8
7,000
5,200
14,000
12,200
10,000
7,000
5/8
10,800
8,000
22,000
18,800
15,200
10,800
5/8
3/4
15,200
11,400
30,000
26,000
22,000
15,200
3/4
7/8
20,000
15,200
40,000
34,000
28,000
20,000
7/8
11-17
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Chapter 11
Wire Rope and Slings
11-18
DOE-STD-1090-2001
11.3.2.1 Inspections
11.3.2.2 Proof-Testing
1.
2.
3.
4.
Experience gained on the service life
of slings used in similar circumstances.
2.
200 percent of the vertical rated
capacity for mechanical-splice single-leg slings
and endless slings.
f.
Test loads described above shall be
accurate to within -5 percent, +0 percent of
stipulated values. A written letter of
certification by the manufacturer or a pull test
witnessed and certified in writing by a qualified
person is acceptable.
1.
Ten randomly distributed broken
wires in one rope lay or five broken wires in one
strand in one rope lay.
2.
Wear or scraping of one-third the
original diameter of the outside individual wire.
11.3.2.3 Operation
a. The following shall apply to all personnel
who use wire-rope slings:
3.
Kinking, crushing, birdcaging, or any
other damage resulting in distortion of the rope
structure.
4.
1.
Start and stop slowly; sudden starts
and stops dramatically increase the stresses in
hoist ropes and slings. Lift slowly until the load
is suspended to minimize swinging.
5.
End attachments that are cracked,
deformed, or worn.
2.
Loads shall be set on blocks. Do not
pull a sling from under a load that is resting on
the sling.
6.
Corrosion of the rope or end
attachments.
3.
Ensure that wire-rope slings are
protected against weather, chemicals, solvents,
and high temperatures.
f.
Hooks shall be inspected according to
Chapter 12, Rigging Accessories.
11-19
Chapter 11
Wire Rope and Slings
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DOE-STD-1090-2001
4.
Permanently remove from service
fiber-core rope slings that have been exposed to
temperatures in excess of 180 degrees F (82
degrees C).
5.
Obtain the manufacturer's written
approval for use of wire rope slings of any grade
at temperatures between 400 degrees F (204
degrees C) and -60 degrees F (-51 degrees C).
6.
Extremely low temperatures (less
than 0 degrees F) may cause brittle fractures.
Under these conditions, sudden loading should
be avoided and the rope should be carefully
observed while the load is being applied.
7.
8.
Do not use single-leg wire-rope
slings unless proper precautions are taken to
prevent suspended loads from rotating.
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iv.
v.
vi.
Chapter 11
Wire Rope and Slings
Rust or corrosion.
ii.
iii. Kinks.
9.
Rigging shall be configured such that
slings do not reeve or slip through the hook.
i.
11-20
DOE-STD-1090-2001
11-21
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
ii.
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ii.
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iv.
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v.
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vi.
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3.
Wire-rope sling eyes with thimbles
shall be made with a thimble having a ratio of
thimble diameter (D) to rope diameter (d) of 3 or
more (D/d greater than or equal 3).
4.
Do not use wedge sockets or
wire-rope clips on slings used for critical lifts.
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1.
All provisions of paragraph
11.3.2.3.a, also shall apply to critical lifts.
2.
Wire-rope slings used for critical-lift
service shall have an initial proof load test. If
proof testing cannot be verified, the wire-rope
sling(s) shall be proof tested before being used
to make a critical lift. As a minimum, the proof
load shall be equal to the rated capacity but shall
not exceed:
i.
5.
Ensure that working loads of
wire-rope slings do not exceed their rated
capacities.
6.
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7.
Use thimble eyes for slings to be
joined end-to-end.
8.
Adequate clearance is
maintained between the attached
slings and other parts or
surfaces of the component or
equipment.
ii.
11-22
DOE-STD-1090-2001
iv.
v.
vi.
f.
Extremely low temperatures (less than 0
degrees F) may cause brittle fractures. Under
these conditions, sudden loading should be
avoided and the load should be lifted a very
short distance while the chains are carefully
inspected.
9.
In addition to marking requirements
listed for ordinary lifts, other items may need to
be marked as determined on a case-by-case
basis, such as the reach, type, weight of the sling
assembly, and rated capacity.
i.
Chains should not be lubricated when in
use because this might make them dangerous to
handle. Chains should be cleaned periodically
to remove abrasive grit and to facilitate
inspection.
j.
The total load that can be lifted safely with
steel-chain slings depends on the manner by
which the slings are attached to the load. If all
legs of a steel-chain sling are hooked back into
the master link, the safe-load capacity of the
whole sling may be increased by 100 percent if
the capacity of the master link is not exceeded.
11-23
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
1.
Hang chain in a vertical position, if
practicable, for preliminary inspection. Chain
should hang reasonably straight if links are not
distorted.
2.
Accurately measure the reach (inside
of crane ring to inside of hook) under no load
when new and at each inspection, and keep a
record of increase in length; an increase in
length may be due to stretch (sign of overload or
wear).
3.
Check for localized stretch and wear.
Lift each link from its seat and visually inspect
for grooving. If grooving is noticed, verify
stock diameter of link to be within the minimum
safe dimensions in the table below. Reject chain
if it does not meet the requirements in the table.
4.
Remove the assembly from service if
wear at any point of any chain link exceeds that
shown in Table 11-11.
5.
Round out sharp transverse nicks by
grinding. If the minimum dimensions are
reduced below those values specified in
Table 11-11, remove the assembly from service.
6.
f.
Do not straighten deformed hooks or other
attachments on the job. Assemblies with such
defects shall be reconditioned by the
manufacturer or discarded.
11.3.3.3 Proof-Testing
a. Single-leg and endless alloy-steel chain
slings shall be certified as having been
proof-tested to 200 percent of the rated capacity
prior to initial use.
Chapter 11
Wire Rope and Slings
11-24
DOE-STD-1090-2001
Table 11-10. Alloy steel chain slings in pounds Design Factor = 4:1
Size in inches
Single Leg
60
Two Legs
45
Two Legs
30
Two Legs
Size in inches
9/32
3,500
6,100
4,900
3,500
9/32
3/8
7,100
12,300
10,000
7,100
3/8
12,000
20,800
17,000
12,000
5/8
18,100
31,300
25,600
18,100
5/8
3/4
28,300
49,000
40,000
28,300
3/4
7/8
34,200
59,200
48,400
34,200
7/8
47,700
82,600
67,400
47,700
1 1/4
72,300
125,200
102,200
72,500
1 1/4
(CFR 1910.184/ANSI/ASME B30.9)
Notes:
(1)
Other grades of proof tested steel chain include Proof Coil (Grade 28), Hi-Test (Grade 43) Chain and Transport (Grade 70)
Chain. These grades are not recommended for overhead lifting and therefore are not covered in the applicable standards.
(2)
Rating of multileg slings adjusted for angle of loading between the inclined leg and the horizontal plane of the load.
11-25
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Table 11-11. Maximum allowable wear
of chains.
Chain size
(in.)
Maximum
allowable wear
(in.)
1/4
3/8
5/8
3/4
7/8
1
1-1/4
3/64
5/64
7/64
9/64
10/64
11/64
12/64
16/64
iv.
v.
vi.
7.
Do not weld or perform local repairs
on chain slings. All defective chain slings
should be returned, through a formal procedure,
to the manufacturer for examination, repair, and
recertification.
8.
slings.
9.
Maintain latches on hooks in good
condition.
11.3.3.4 Operation
2.
Shorten chain slings by hooking back
into the chain, into the master link, or with grab
hooks. Do not shorten by knotting, twisting,
bolting, or inserting the tip of the hook into a
link.
12.
3.
Do not hammer a chain to force it
into position.
4.
Protect chain slings from sharp
corners that might bend the links. Use a suitable
pad to prevent gouging or bending of the chain
links, as well as possible scarring of the load.
5.
When making choker hitches with
chain slings, always face the hook opening out
and away from the pull of the sling so that the
hooks will not slip out when slack is taken out of
the sling.
6.
ii.
Size.
ii.
Manufacturer's grade.
iv.
Reach.
v.
Number of legs.
vi.
Sling manufacturer.
Chapter 11
Wire Rope and Slings
i.
11-26
DOE-STD-1090-2001
17. This information may be stenciled or
stamped on a metal tag or tags affixed to the
sling.
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Classification
Heavy duty
Carbon steel
Stainless steel
35-CS
35-SS
Medium duty
Carbon steel
Stainless steel
43-CS
43-SS
Carbon steel
Stainless steel
59-CS
59-SS
Light duty
1.
At least the same rated capacity as
the fabric.
2.
No visible permanent deformation
after proof-testing.
e. The fabric and handles shall be so joined
that:
1.
reduced.
2.
The load is evenly distributed across
the width of the fabric.
3.
fabric.
f.
Metal-mesh slings may be painted, plated,
impregnated with elastomers such as neoprene
or polyvinyl chloride (PVC), or otherwise
suitably coated. The coating shall not diminish
the rated capacity of a sling.
g. The design factor for metal-mesh slings
shall be a minimum of 5:1 based upon breaking
strength.
h. Metal-mesh slings shall not be used to lift
loads greater than the rated capacity, properly
derated for other than straight-pull
configurations (Table 11-13).
d.
i.
Except for elastomer-impregnated slings,
all metal-mesh slings covered by this section
may be used without derating in a temperature
range from -20 degrees F (-29 degrees C) to 550
degrees F (288 degrees C).
j.
All metal-mesh slings covered by this
section and impregnated with PVC or neoprene
shall be used only in a temperature range from 0
degrees F (-18 degrees C) to 200 degrees F (93
degrees C).
11-27
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
11.3.4.1 Inspections
a. Users of metal-mesh sling shall visually
inspect all metal-mesh slings before each use.
7.
A 15 percent reduction of the original
cross-sectional area of metal at any point around
a handle eye.
8.
Any distortion or twisting of either
end fitting out of its plane.
10.
11.3.4.2 Proof-Testing
3.
Reduction in wire diameter of
25 percent due to abrasion or 15 percent due to
corrosion.
4.
Lack of flexibility due to distortion
of the mesh.
5.
Distortion of the female handle so the
depth of the slot is increased by more than 10
percent.
Chapter 11
Wire Rope and Slings
9.
11-28
DOE-STD-1090-2001
Table 11-13. Load capacity of carbon and stainless-steel metal-mesh slings in pounds
Design Factor = 5:1
Basket or
two legs
60
Basket or
two legs
45
Basket or
two legs
30
Basket or
two legs
Sling width(in.)
Sling width(in.)
Vertical or choker
1,500
3,000
2,600
2,100
1,500
2,700
5,400
4,700
3,800
2,700
4,000
8,000
6,900
5,600
4,000
6,000
12,000
10,400
8,400
6,000
8,000
16,000
13,800
11,300
8,000
10
10,000
20,000
17,000
14,100
10,000
10
12
12,000
24,000
20,700
16,900
12,000
12
14
14,000
28,000
24,200
19,700
14,000
14
16
16,000
32,000
27,700
22,600
16,000
16
1,350
2,700
2,300
1,900
1,400
2,000
4,000
3,500
2,800
2,000
2,700
5,400
4,700
3,800
2,700
4,500
9,000
7,800
6,400
4,500
6,000
12,000
10,400
8,500
6,000
10
7,500
15,000
13,000
10,600
7,500
10
12
9,000
18,000
15,600
12,700
9,000
12
14
10,500
21,000
18,200
14,800
10,500
14
16
12,000
24,000
20,800
17,000
12,000
16
900
1,800
1,600
1,300
900
1,400
2,800
2,400
2,000
1,400
2,000
4,000
3,500
2,800
2,000
3,000
6,000
5,200
4,200
3,000
4,000
8,000
6,900
5,700
4,000
10
5,000
10,000
8,600
7,100
5,000
10
12
6,000
12,000
10,400
8,500
6,000
12
14
7,000
14,000
12,100
9,900
7,000
14
16
8,000
16,000
13,900
11,300
8,000
16
11-29
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
r.
Metal-mesh slings used in pairs should be
attached to a spreader beam.
11.3.4.3 Operation
a. The following shall apply to all personnel
who use metal-mesh slings:
1.
Ensure that the weight of the load is
within the rated capacity of the sling.
2.
Ensure that metal-mesh slings have
suitable characteristics and rated capacity for the
load and environment.
2.
Rated load in vertical, basket, and
choker hitches.
3.
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j.
Do not pull metal-mesh slings from under a
load when the load is resting on the sling.
l.
1.
Be of sufficient strength to meet the
sling manufacturer's requirements.
2.
3.
Have selvage edges and not be split
from its woven width.
c.
1.
Of sufficient strength to sustain twice
the rated capacity without permanent
deformation.
2.
Of a minimum breaking strength
equal to that of the sling.
Chapter 11
Wire Rope and Slings
11-30
DOE-STD-1090-2001
3.
Free of all sharp edges that would in
any way damage the mesh.
j.
Despite their inherent toughness,
synthetic-web slings can be cut by repeated use
around sharp-cornered objects. They eventually
show signs of abrasion when they are repeatedly
used to hoist rough-surfaced products. There
are, however, protective devices offered by most
sling manufacturers that minimize these effects
(see Figure 11-19). Other protective devices
include:
1.
Buffer strips of leather, nylon, or
other materials that are sewn on the body of a
sling protect against wear. Leather pads are the
most resistant to wear and cutting, but are
subject to weathering and gradual deterioration.
They are not recommended in lengths over 6 ft
due to the different stretching characteristics of
leather and webbing. On the other hand,
nylon-web wear pads are more resistant to
weathering, oils, grease, and most alkalis; and
they stretch in the same ratio as the sling body.
f.
The design factor for synthetic-web slings
shall be a minimum of 5:1 based upon breaking
strength.
g. Rated capacities are affected by the type of
hitch used and by the angle from the vertical
when used as multilegged slings or in basket
hitches. The sling manufacturer shall supply
data on these effects.
2.
Edge guards consist of strips of
webbing or leather sewn around each edge of the
sling. This is necessary for certain applications
where the sling edges are subject to damage.
3.
Sleeve- or sliding-tube-type wear
pads are available for slings used to handle
material having sharp edges. They can be
positioned on the sling where required, do not
move when the sling stretches, adjust to the
load, and cover both sides of the sling.
4.
Reinforcing strips that double or
triple the eye's thickness and greatly increase its
life and safety can be sewn into the sling eyes.
2.
Standard Eye and EyeWebbing is
assembled and sewn to form a flat-body sling
with an eye at each end and the eye openings in
the same plane as the sling body. The eyes may
either be full web width or may be tapered by
being folded and sewn to a width narrower than
the webbing width.
5.
Coatings can be applied to provide
added resistance to abrasion and chemical
damage. These treatments also increase the
coefficient of friction, affording a better grip
when loads with slippery surfaces are to be
handled. These coatings can be brightly colored
for safety or load-rating purposes.
3.
Twisted EyeAn eye-and-eye type
that has twisted terminations at both ends. The
eye openings are at 90 degrees to the plane of
the sling body. This configuration is also
available with either full-width or tapered eyes.
6.
Cotton-faced nylon webbing can be
used for hoisting rough-surfaced material.
k. The synthetic-web sling capacities listed in
Tables 11-14 and 11-15 are approximate only
and are based on nylon webbing having
breaking strengths between 6,000 and
9,000 lb/in. of webbing width. The capacities
are also based on a 5:1 design factor and assume
that the end fittings are of adequate strength.
i.
In place of the sewn eyes, synthetic-web
slings are also available with metal end fittings
(see Figure 11-18). The most common are
triangle and choker hardware. Combination
hardware consists of a triangle for one end of the
sling and a triangle/rectangle choker attachment
for the other end. With this arrangement, both
choker and basket hitches, as well as straight
hitches, may be rigged. They help reduce wear
in the sling eyes and thus lengthen sling life.
11-31
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Chapter 11
Wire Rope and Slings
11-32
DOE-STD-1090-2001
d. Slings shall be removed from service if any
of the following defects are visible:
l.
Although safe working loads for bridle
hitches in the choker or double-basket
configuration are provided, they should be used
only with extreme caution because, as the sling
angle decreases, one edge of the web will take
all the load, producing a risk of tearing (see
Figure 11-20).
1.
2.
surface.
3.
4.
5.
Wear or elongation exceeding the
amount recommended by the manufacturer.
6.
Distortion of fittings.
7.
8.
Missing or illegible sling
identification.
2.
The proof load for multiple-leg bridle
slings shall be applied to the individual legs and
shall be 200 percent of the vertical rated
capacity of a single-leg sling. Master links to
which multiple-leg slings are connected shall be
proof-loaded to 200 percent times the force
applied by the combined legs.
11.3.5.1 Inspections
11-33
Chapter 11
Wire Rope and Slings
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DOE-STD-1090-2001
Chapter 11
Wire Rope and Slings
11-34
DOE-STD-1090-2001
Table 11-14. Load capacity of synthetic web slings in pounds Design Factor = 5:1
(eye and eye, twisted eye, triangle fittings, choker fittings)
Web
width
(in.)
Vertical
Choker
Web
width
(in.)
Basket or
two legs
1,200
900
2,400
2,080
1,700
1,200
2,400
1,800
4,800
4,160
3,400
2,400
3,600
2,700
7,200
6,240
5,100
3,600
4,800
3,600
9,600
8,300
6,800
4,800
6,000
4,500
12,000
10,400
8,500
6,000
7,200
5,400
14,400
12,500
10,200
7,200
2,400
1,800
4,800
5,600
3,400
2,400
4,800
3,600
9,600
8,320
6,800
4,800
7,200
5,400
14,400
12,480
10,200
7,200
9,600
7,200
19,200
16,600
13,600
9,600
12,000
9,000
24,000
20,800
17,000
12,000
14,400
10,800
28,800
25,000
20,400
14,400
For an endless sling with vertical hitch carrying a load of such size as to throw the legs more than 5 deg. off vertical use rated
load data for eye and eye sling, basket hitch and corresponding leg angles.
(2)
(3)
Choker hitch values apply only to choke angles greater than 120 degrees.
11-35
Chapter 11
Wire Rope and Slings
DOE-STD-1090-2001
Table 11-15. Load capacity of synthetic web slings in pounds Design Factor = 5:1
(eye and eye, twisted eye, triangle fittings, choker fittings)
Web
width
(in.)
Vertical
Choker
Web
width
(in.)
Basket or
two legs
1,600
1,280
3,200
2,770
2,260
1,600
3,200
2,560
6,400
5,540
4,520
3,200
4,800
3,840
9,600
8,320
6.780
4,800
6,400
5,120
12,800
11,090
9,040
6,400
8,000
6,400
16,000
13,860
11,300
8,000
9,600
7,680
19,200
16,640
13,560
9,600
3,200
2,560
6,400
5,540
4,520
3,200
6,400
5,120
12,800
11,090
9,040
6,400
8,880
7,100
17,760
15,390
12,540
8,880
11,520
9,210
23,040
19,660
16,270
11,520
14,000
11,200
28,000
24,260
19,775
14,000
16,320
13,050
32,640
28,280
23,050
16,320
For an endless sling with vertical hitch carrying a load of such size as to throw the legs more than 5 deg. off vertical use rated
load data for eye and eye sling, basket hitch and corresponding leg angles.
(2)
(3)
Choker hitch values apply only to choke angles greater than 120 degrees.
Chapter 11
Wire Rope and Slings
11-36
DOE-STD-1090-2001
Table 11-16. Load capacity of Single Leg Polyester Roundslings in pounds
Endless and Eye to Eye Type Design Factor = 5:1
Size
(Note 1)
Vertical
Choker
Basket or
two leg
Size
(Note 1)
2,600
2,100
5,200
4,500
3,700
2,600
5,300
4,200
10,600
9,300
7,500
5,300
6,400
6,700
16,800
14,500
11,900
6,400
10,600
8,500
21,200
18,400
15,000
10,600
13,200
10,600
26,400
22,900
18,700
13,200
16,800
13,400
33,600
29,100
23,800
16,800
21,200
17,000
42,400
36,700
30,000
21,200
25,000
20,000
50,000
43,300
35,400
25,000
31,000
24,800
62,000
53,700
43,800
31,000
10
40,000
32,000
80,000
69,300
56,600
40,000
10
11
53,000
42,400
106,000
91,800
74,900
53,000
11
12
66,000
52,800
132,000
114,300
93,300
66,000
12
13
90,000
72,000
180,000
155,900
127,300
90,000
13
Chapter 11
Wire Rope and Slings
11-40
DOE-STD-1090-2001
15.2 DEFINITIONS
APPOINTED: Assigned specific
responsibilities by the employer or the
employer's representative.
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Note: In the text, use of the imperative voice (as in Ensure that the load is balanced) or of the term shall refers
to mandatory actions, whereas the term should refers to recommended actions.
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
15-2
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DOE-STD-1090-2001
15-3
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
DOE-STD-1090-2001
General note for Figures 15-5 through 15-10:
The boom may have a base boom structure of sections (upper and lower) between or beyond which
additional sections may be added to increase its length, or it may consist of a base boom from which one
or more boom extensions are telescoped for additional length. These illustrations show some types.
15-4
DOE-STD-1090-2001
15-5
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
DOE-STD-1090-2001
QUALIFIED INSPECTOR: One whose
competence is recognized by the authority
having jurisdiction and whose qualification to
perform specific inspection activities has been
determined, verified, and attested to in writing.
QUALIFIED ENGINEER/QUALIFIED
ENGINEERING ORGANIZATION: An
engineer or engineering organization whose
competence in evaluation of the type of
equipment in question has been demonstrated to
the satisfaction of the responsible manager.
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
15-6
DOE-STD-1090-2001
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3.
The operator did not have at least
eight hours off, immediately prior to the work
shift containing the person.
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15-41
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
DOE-STD-1090-2001
2.
Cranes equipped with outriggers
shall have outriggers extended in accordance
with the manufacturers instructions.
3.
Crane systems, controls, operator
aids, and safety devices are activated and
functioning properly.
4.
No interferences exist.
5.
The total weight of the loaded
personnel lift platform (including personnel) and
related rigging shall not exceed 50 percent of the
crane rating under the planned conditions of use.
6.
The personnel lift platform shall not
be loaded in excess of its rated load capacity.
The number of employees occupying the
platform shall not exceed the number required
for the work being performed.
15.6.1.3 Trial Lift
a. Each shift, before personnel initially enter
the personnel lift platform, the operator and
signaler shall conduct a trial lift. The trial lift
shall include:
1.
Loading the unoccupied personnel
platform to at least the maximum anticipated
load. Materials and tools to be used during the
actual lift, if secured to prevent displacement,
can be in the platform for the trial lift.
2.
The trial lift shall be made from the
location where personnel will enter the platform
to each location where the platform will be
hoisted and positioned. It is acceptable to
perform a single trial lift on each shift for all
locations to be reached from a single setup
position.
3.
The trial lift shall be repeated
whenever:
i.
ii.
iii.
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
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15-42
6.
Ropes are properly seated on drums
and sheaves.
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7.
level.
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1.
A visual inspection of the crane,
rigging, and personnel lift platform shall be
conducted by a qualified inspector. Any defects
found that create a safety hazard shall be
corrected prior to hoisting personnel.
2.
The platform shall be lifted a few
inches and inspected to ensure that it is secure
and properly balanced.
15.6.1.4.3 Lifting Personnel
a. Prior to hoisting personnel in a personnel
lift platform ensure that:
1.
No hazardous conditions exist with
the platform and its associated rigging.
2.
The hoist line is not wrapped around
any part of the platform.
3.
4.
Multiple-part lines are not twisted
around each other.
5.
The primary attachment is centered
over the platform.
DOE-STD-1090-2001
8.
The crane has an anti two-block
device installed and operational.
b. Employees being hoisted or working in a
personnel lift platform shall:
1.
Remain in continuous sight of, and in
direct communication with, the operator or
signaler. In situations where direct visual
contact with the operator is not possible and the
use of a signaler would create a hazard for that
person, direct communication alone (such as a
two-way radio) may be used.
2.
Keep all parts of their bodies inside
the suspended personnel lift platform during
raising, lowering, and positioning to avoid pinch
points.
3.
Wear body harnesses with lanyards
attached to the lower load block or overhaul
ball, or to a structural member within the
platform that is capable of supporting a fall
impact.
4.
Not stand on or work from the top
rail, midrail, or toe board of the suspended
personnel platform.
5.
When working above water, the
requirements of 29 CFR 1926.106 (Occupational
Safety and Health Regulations for Construction)
shall also apply.
6.
When welding is being performed
from the personnel lift platform, the electrode
holders shall be protected from contact with
metal components of the personnel platform.
c. Operators of cranes hoisting personnel in a
personnel lift platform shall:
1.
Before commencing or continuing
the lift, consult with the designated leader when
ever there is any doubt as to the safety of the lift.
2.
Remain at the controls when the
personnel lift platform is occupied.
3.
Operate the crane so that lowering
will be power-controlled (no free-fall).
4.
Ensure movement of the personnel
lift platform is performed in a slow, controlled,
cautious manner with no sudden movements of
the crane or the platform. The lifting or
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15-43
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
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DOE-STD-1090-2001
c. Cranes with telescoping booms shall be
equipped with a device to indicate clearly to the
operator, at all times, the boom's extended
length, or an accurate determination of the load
radius to be used during the lift shall be made
prior to hoisting personnel.
d. A positive-acting device shall be used that
prevents contact between the load block or
overhaul ball and the boom tip (anti-twoblocking device), or a system shall be used that
deactivates the hoisting action before damage
occurs in the event of a two-blocking situation
(two-block damage-prevention feature).
e. Cranes having booms in which lowering is
controlled by a brake without aid from other
devices which slow the lowering speeds is
prohibited.
f.
Crane load lines shall be capable of
supporting, without failure, at least seven times
the maximum intended load, except where
rotation resistant rope is used, the lines shall be
capable of supporting without failure, at least ten
times the maximum intended load.
g. Hydraulic cranes shall have check valves
or other devices that will prevent uncontrolled
movement in the event of system failure, engine
failure, or hose rupture.
h. Cranes shall have a means to prevent
retraction of hydraulically or pneumatically
activated outriggers or stabilizers in the event a
hydraulic or pneumatic line fails.
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i.
Pendant supported, jib type, boon
extensions without positive stops are prohibited
for personnel lifting.
j.
Hooks on overhaul ball assemblies, lower
load blocks, or other attachment assemblies shall
be of the type that can be closed and locked,
eliminating the hook throat opening. (Figure 1518). Alternatively, an alloy anchor type shackle
with a bolt, nut and retaining pin may be used.
15.6.1.6 Personnel Lift Platform
15.6.1.6.1 Platform Design and
Construction
There is no attempt to comprehensively address
platform design and construction in this section.
Nevertheless, because many platform design and
construction features can be observed and
should be known by the platform user, (See
Figures 15-19) the following key design and
construction requirements are presented:
a. The personnel lift platform and suspension
system shall be designed by a qualified person
competent in structural design and familiar with
national consensus standards governing
personnel platform design.
b. All welding of the platform shall be
performed by a qualified welder in accordance
with ANSI/AWS D1.1. Where special steels or
other materials are used, the manufacturer shall
provide welding procedures. Welds shall be
inspected by a qualified inspector.
c.
2.
A plate specifying its empty weight
and its rated load capacity or maximum intended
load.
3.
Perimeter protection consisting of a
top rail approximately 45 in. (115 cm) high, a
toe board at least 4 in. (10 cm) high, and a
midrail approximately halfway between the top
rail and the toe board.
4.
A grab rail inside the personnel lift
platform to minimize hand exposure.
5.
Anchorage points within the platform
for attaching personnel fall protection lanyards.
6.
The sides of the platform enclosed
from the toe board to the midrail with solid
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
15-44
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DOE-STD-1090-2001
construction or expanded metal having openings
no greater than in. (1.27 cm).
7.
Platform access gates, including
sliding or folding types, if installed, shall have a
positive acting device to restrain the gate from
accidental opening. Swinging type access gates
shall open only to the interior of the personnel
lift platform.
8.
Rough edges exposed to contact by
employees surfaced (ground smooth) to prevent
injury.
9.
High-visibility color or marking for
easy identification.
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15-45
2.
Two or three-leg system - design
factor of five for each leg.
3.
Four-leg system - design factor of
five with only three legs under stress.
4.
Where rotation resistant rope is used,
the slings shall be capable of supporting without
failure at least ten times the maximum intended
load.
b. Sling suspension systems shall utilize a
master link or safety type shackle to connect the
personnel lift platform to the load line to ensure
that the load is evenly divided among the
suspension system legs.
c. The suspension system shall be designed to
minimize tipping of the platform due to
movement of employees occupying the
platform.
d. The sling suspension system attaching the
personnel lift platform to the hoist line shall not
be used for any other purpose when not hoisting
personnel.
e. Shackles used in any part of the suspension
system shall be a safety type (bolt-type shackle
with nut and cotter pin).
f.
All eyes in wire rope slings shall be
fabricated with thimbles.
g. Wire rope clips, wedge sockets, or knots
shall not be used in suspension system sling
assemblies.
h. Synthetic webbing, natural or synthetic
fiber rope shall not be used for the suspension
systems.
i.
Chain sling suspension systems shall use a
minimum of grade 80 chain.
Chapter 15
Construction Hoisting and Rigging
Equipment Requirements
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The following industry guides are available from the N.C. Department of Labors Occupational Safety and
Health Division:
1#1. A Guide to Safety in Confined Spaces
1#2. A Guide to Procedures of the N.C. Safety and Health Review Commission (downloadable PDF ONLY)
1#3. A Guide to Machine Safeguarding
1#4. A Guide to OSHA in North Carolina
1#5. A Guide for Persons Employed in Cotton Dust Environments (downloadable PDF ONLY)
1#6. A Guide to Lead Exposure in the Construction Industry (downloadable PDF ONLY)
1#7. A Guide to Bloodborne Pathogens in the Workplace
1#8. A Guide to Voluntary Training and Training Requirements in OSHA Standards
1#9. A Guide to Ergonomics
#10. A Guide to Farm Safety and Health (downloadable PDF ONLY)
#11. A Guide to Radio Frequency Hazards With Electric Detonators (downloadable PDF ONLY)
#12. A Guide to Forklift Operator Training
#13. A Guide to the Safe Storage of Explosive Materials (downloadable PDF ONLY)
#14. A Guide to the OSHA Excavations Standard
#15. A Guide to Developing and Maintaining an Effective Hearing Conservation Program
#16. A Guide to Construction Jobsite Safety and Health/Gua de Seguridad y Salud para el Trabajo de Construccin
#17. A Guide to Asbestos for Industry
#18. A Guide to Electrical Safety
#19. A Guide to Occupational Exposure to Wood, Wood Dust and Combustible Dust Hazards (downloadable PDF ONLY)
#20. A Guide to Cranes and Derricks
#23. A Guide to Working With Electricity
#25. A Guide to Personal Protective Equipment
#26. A Guide to Manual Materials Handling and Back Safety
#27. A Guide to the Control of Hazardous Energy (Lockout/Tagout)
#28. A Guide to Eye Wash and Safety Shower Facilities
#29. A Guide to Safety and Health in Feed and Grain Mills (downloadable PDF ONLY)
#30. A Guide to Working With Corrosive Substances (downloadable PDF ONLY)
#31. A Guide to Formaldehyde (downloadable PDF ONLY)
#32. A Guide to Fall Prevention in Industry
#32s. Gua de Prevencin de las Cadas en la Industria (Spanish version of #32)
#33. A Guide to Office Safety and Health (downloadable PDF ONLY)
#34. A Guide to Safety and Health in the Poultry Industry (downloadable PDF ONLY)
#35. A Guide to Preventing Heat Stress
#38. A Guide to Safe Scaffolding
#40. A Guide to Emergency Action Planning
#41. A Guide to OSHA for Small Businesses in North Carolina
#41s. Gua OSHA para Pequeos Negocios en Carolina del Norte (Spanish version of #41)
#42. A Guide to Transportation Safety
#43. A Guide to Combustible Dusts
#44. A Guide to Respiratory Protection